METHOD AND DEVICE FOR MANUFACTURING A FLAT RIBBON CONDITIONER

Abstract

The present invention relates to a method for manufacturing a flat ribbon cable (1) with at least a first and a second cable (2, 3), wherein the method comprises the following steps: providing a base substrate (4), providing at least the first and second cables (2, 3) and arranging the at least first and second cables (2, 3) on the base substrate (4), wherein the at least first and second cables (2, 3) are arranged at a distance (A) from each other on the base substrate (4), providing a cover substrate (5) and arranging the cover substrate (5) over the base substrate (4), and feeding the base substrate (4) with the at least first and second cables (2, 3) and the cover substrate (5) to an ultrasonic welding device (20) and joining the base substrate (4) with the cover substrate (5) at least at the distance (A) between the at least first and second cables (2, 3) by ultrasonic welding.The present invention further relates to a device (10) for manufacturing a flat ribbon cable (1).

Description

Technical field

[0001] The invention relates to a method and a device for manufacturing a flat ribbon cable, in particular a mixed composite flat ribbon cable made of different cable types. State of the art

[0002] Flat ribbon cables are experiencing increasing interest, particularly in the automotive sector, for the transmission of electrical and / or optical signals. A flat ribbon cable can be composed of several identical and / or different individual conductors (hybrid construction). Other applications for flat ribbon cables include robotics, building technology, mechanical engineering, and / or medical technology.

[0003] Various methods for manufacturing such flat ribbon cables are described in the prior art. One method is extrusion, in which several individual conductors are fed into an extruder. The heated extruder then encases the conductors with thermoplastic materials. Another method is lamination. This method produces laminated flat ribbon cables, and different material and conductor combinations can be used. Another method is the winding tape method, in which a cable or hybrid cable with a variety of wire sizes and types is wrapped using a winding tape. Finally, there is the option of manually feeding a conventional round cable consisting of several cable types, after stripping, into a clamping device in a defined arrangement. In this device, the individual conductors of the round cable are arranged side by side, for example, to be fed into a connector.

[0004] However, the described state-of-the-art methods have disadvantages.

[0005] Thermal extrusion sheathing has the disadvantages of long start-up times until the tool reaches operating temperature, a very long production line due to long cooling sections after extrusion, the need for multiple process steps, and the inability to operate in stop-and-go mode, meaning the extrusion process cannot be interrupted. Furthermore, a very complex tool change on the extrusion die is unavoidable, and the dies are not flexible enough to be used for different cable types; each cable type combination requires its own separate extrusion die.

[0006] Lamination has the disadvantages that heat must be applied externally, leading to heating of the tool and components. This can potentially damage sensitive components due to heat generation. Furthermore, additional processes for heating and cooling the laminating films are necessary. Overall, the process is more complex due to the multiple process steps. Balancing these steps is also required, limiting the process speed. Other considerations include material compatibility; for example, materials with a higher temperature resistance than the sheathing of the individual cables cannot be used. It must also be ensured that all cable components tolerate the lamination conditions. Finally, delamination due to thermal sensitivity must be taken into account.insufficient bonding due to limited thermal stress, and finally, high energy consumption due to the necessary heat.

[0007] A wrapping tape has the disadvantages that the cable bundles can only be wound together at the end of the assembly, parallel processing of all cable ends from the connector is very complex, high costs are incurred due to the wrapping tape and its application, the cables can twist during winding, and the ends of the wrapping tape can come undone if handled improperly.

[0008] Clamping individual cables in a clamping device has the disadvantages that a very high level of effort is required in the plugging process, this process is difficult or almost impossible to automate, the design of the cable clamping (forces) is difficult for the different cable types, additional fixing with adhesive is necessary for high tensile forces and there are comparatively high costs for the additional component (clamping device). Description of the invention

[0009] It is therefore an object of the present invention to provide a method and a device for the manufacture of a flat ribbon cable, wherein temperature-independent integration of different conductor types should be possible, the use of adhesives or solvents should be avoided, and high economic efficiency and precision should be achieved.

[0010] The aforementioned problem is solved by a method for manufacturing a flat ribbon cable according to claim 1 and by a device for manufacturing a flat ribbon cable according to claim 4. Further advantageous embodiments of the invention can be found in the dependent claims, the description, and the drawings.

[0011] In particular, the above-mentioned problem is solved by a method for manufacturing a flat ribbon cable with at least a first and a second conductor, the method comprising the following steps: providing a base substrate from a first storage location, wherein the base substrate comprises a film-like plastic and extends in a ribbon-like manner along a first direction; providing at least the first and second conductors from a second storage location and arranging the at least first and second conductors on the base substrate, wherein the at least first and second conductors are arranged at a distance from each other on the base substrate and extend along the first direction; providing a cover substrate from a third storage location, wherein the cover substrate comprises a film-like plastic and extends in a ribbon-like manner along the first direction, and arranging the cover substrate over the base substrate.so that at least the first and second lines are arranged between the base substrate and the top substrate, and the base substrate, along with the at least first and second lines and the top substrate, is fed to an ultrasonic welding device, and the base substrate is joined to the top substrate at least at the distance between the at least first and second lines via ultrasonic welding.

[0012] This process reliably and quickly bonds the base substrate to the cover substrate, incorporating the conductors located between the two substrates to create a stable and reliable flat ribbon cable. The bond requires no additional materials such as adhesives or solvents. The process is independent of the cable sheathing materials. The bond is permanent even under a wide range of environmental conditions, including heat, cold, and humidity. The ultrasonic welding itself acts only directly on the ultrasonic weld seams and has no negative impact on the conductors or other areas of the base or cover substrate that are not directly ultrasonically welded. In other words, this process applies the generated heat more precisely and selectively to the weld seam, heating it to at least the melting point of the base and / or cover substrate material.Especially in ultrasonic welding of plastics, heat is transferred precisely and in a targeted manner to the weld seam. The weld zone (at the weld seam) is heated to the point where it reaches the melting temperature of the material being welded, or optionally, the highest melting temperature of the materials being welded. Furthermore, ultrasonic welding is fast and requires little space. Depending on the conductors used in the manufacturing process, a wide variety of flat ribbon cables can be produced. The manufacturing process is highly adaptable to the desired flat ribbon cables. A flat ribbon cable produced using this method exhibits precise positioning of the integrated conductors. This precise positioning is ideal for subsequent processes, such as 3D laser stripping.

[0013] Preferably, the first and second conductors comprise different conductor types. Using different conductor types to manufacture a flat ribbon cable increases the flexibility in its production.

[0014] Preferably, the process further comprises the following steps: folding the flat ribbon cable at a bend and ultrasonic welding of the folded flat ribbon cable at new ultrasonic welds, thus forming a multi-layer flat ribbon cable. Folding and re-ultrasound welding at new ultrasonic welds are simple process steps that can also be automated. Ultrasonic welding at new ultrasonic welds has the advantage of avoiding potential negative effects from or on previous ultrasonic welds. Furthermore, the new, additional ultrasonic welds ensure increased reliability of the connection and the multi-layer flat ribbon cable.

[0015] The above-mentioned problem is further solved in particular by a device for producing a flat ribbon cable with at least a first and a second cable, wherein the device has at least a first storage unit for providing a base substrate, at least a second storage unit for providing a first and a separate second cable and a third storage unit for providing a cover substrate, an ultrasonic welding device for ultrasonic welding of the base substrate to the cover substrate and a feeding device for feeding the base substrate with at least the first and second cables and the cover substrate to the ultrasonic welding device.

[0016] The present device has a simple design and is intended, preferably continuously, to produce a flat ribbon cable by ultrasonic welding. The device is very flexibly adaptable to different cable types.

[0017] Preferably, the ultrasonic welding device comprises at least one oscillating structure and an anvil, and the ultrasonic welding process takes place directly between the oscillating structure and the anvil, preferably by means of vibration of the oscillating structure. The oscillating structure preferably includes at least one sonotrode. The counterpart to the oscillating structure is the anvil, which is preferably constructed from at least one rotatably mounted wheel. During ultrasonic welding, the oscillating structure oscillates against the rotating or stationary wheel(s) to create the material joint through targeted energy transfer. For a change in cable type, only the design of the anvil (i.e., the number and arrangement of the wheel(s)) needs to be adapted when using a planar oscillating structure.

[0018] Preferably, the anvil comprises a plurality of separate wheels, enabling a continuous ultrasonic welding process. A plurality of wheels generally includes one or more wheels. Preferably, the number of wheels corresponds at least to the number of gaps between adjacent conductors, allowing an ultrasonic weld seam to be formed between two adjacent conductors. This allows for the reliable formation of a durable flat ribbon conductor. The wheels are preferably rotatably mounted or driven to rotate, thereby moving the flat ribbon conductor between themselves and the vibrating structure. The wheels enable a continuous ultrasonic welding process, producing at least one continuous ultrasonic weld seam.

[0019] Preferably, at least one wheel has at least one notch on its outer radius, creating a regularly interrupted ultrasonic weld. An interrupted ultrasonic weld places less stress on the base and surface substrates. The notch effectively prevents direct contact between the anvil and the surface substrate, thus preventing ultrasonic welding at that point, and the ultrasonic (generation) process itself, i.e., the vibration of the oscillating structure, does not need to be interrupted.

[0020] Preferably, the vibrating structure has a contour corresponding to the flat ribbon cable. This contour aids in the alignment of at least the first and second conductors and increases the precision of their arrangement within the flat ribbon cable. Furthermore, the contour facilitates the central placement (approximately at the level of the cable's center) of the ultrasonic welds along a third direction of the flat ribbon cable.

[0021] Preferably, the device further comprises a spraying device for applying a foam between the base substrate and the top substrate. The applied foam can serve as a dielectric and / or insulation in the flat ribbon cable.

[0022] Preferably, the device further comprises a fourth storage compartment for providing a film, in particular a metallic film, between the base substrate and the top substrate. By introducing another film, a further (protective) layer can be added to the ribbon cable. In the case of a metallic film, the conductors of the ribbon cable can be shielded against electromagnetic radiation.

[0023] The following description of embodiments is given with reference to the accompanying figures. These show: Fig. 1 a schematic side view of an embodiment of a device for manufacturing a flat ribbon cable; Fig. 2 a schematic cross-sectional view of a first embodiment of the ultrasonic welding device with a first embodiment of a flat ribbon cable; Fig. 3 a schematic cross-sectional view of a second embodiment of the ultrasonic welding device with a second embodiment of a flat ribbon cable; Fig. 4 a schematic cross-sectional view of a third embodiment of the ultrasonic welding device with a third embodiment of a flat ribbon cable; and Fig. 5 a schematic cross-sectional view of a fourth embodiment of the ultrasonic welding device with a first embodiment of a multilayer flat ribbon cable.

[0024] Preferred embodiments are described in detail below with reference to the accompanying figures.

[0025] Fig. Figure 1 shows an embodiment of a device 10 for manufacturing a flat ribbon cable 1. The flat ribbon cable 1 has at least a first and a second conductor 2, 3. The first and second conductor 2, 3 preferably comprise different conductor types, for example, electrical conductors with a specific number of strands 8 surrounded by a sheath 9, wherein the number of strands can vary depending on the conductor type (see Figure 1). Fig. 3) The sheaths can be made of various plastics, for example, a PP sheath, an FEP sheath, or a PVC sheath. In addition to electrical conductors, optical conductors can also be integrated into the flat ribbon cable 1. Furthermore, in addition to conductors for signal transmission, conductors for power transmission can also be integrated into the flat ribbon cable 1.

[0026] The illustrated embodiment of the device 10 comprises at least one first reservoir 11 for providing a base substrate 4, at least one second reservoir 12 for providing a first and a separate second line 2, 3, and a third reservoir 13 for providing a top substrate 5. The base substrate 4 and the top substrate 5 can comprise the same plastic. The plastics of the base and top substrates 4, 5 are preferably thermoplastics. The second reservoir 12 can be further divided into several sub-reservoirs, depending on the line 2, 3. The reservoirs 11, 12, 13 are preferably rollers that enable a continuous supply of substrate 4, 5 and / or lines 2, 3.

[0027] The device 10 further comprises an ultrasonic welding device 20 for ultrasonic welding of the base substrate 4 to the top substrate 5. In particular, the ultrasonic welding device 20 comprises at least one vibrating assembly 21 and an anvil 22. The ultrasonic welding process takes place, preferably by means of a vibration V of the vibrating assembly 21, directly between the vibrating assembly 21 and the anvil 22. The vibration V is preferably effected by a movement along a third direction Z, perpendicular to the first and second directions X, Y, i.e., perpendicular to the plane in which the base substrate 4, the conduits 2, 3, and the top substrate 5 are arranged.

[0028] In the illustrated embodiments of the Fig. In the anvil 22, a plurality of separate wheels 23 are included. The wheels 23 are preferably spring-mounted. At the points where substrate 4, 5 is arranged or clamped between a wheel 23 and the vibrating structure 21, an ultrasonic weld seam 29 is formed during ultrasonic welding. During ultrasonic welding, heat is generated locally at the ultrasonic weld seam 29, sufficient to fuse, i.e., bond, the base substrate 4 with the top substrate 5. Further optional layers between the base and top substrate 4, 5 are also slightly melted, and all layers together form a metallurgical and / or homogeneous bond at the ultrasonic weld seam 29. Without the further optional layers, the two plastic parts or films of the base and top substrate 4, 5 are fused together at the joint, resulting in a strong and permanent bond.A homogeneous weld or joint emphasizes the quality of the seam, namely its strength and consistency, while a material-bonded joint highlights that the bond is formed by the material itself, i.e., the molecular chains of the plastics bond at the weld point. The joint can therefore also be described as a molecular fusion. Molecular fusion specifically indicates a bond at the molecular level. The permanent bonding of at least the base and top substrates 4, 5 fixes and secures the intervening conductors 2, 3, ensuring they retain their position permanently. The wheels 23 are rotatably mounted, enabling a continuous ultrasonic welding process. In one embodiment, at least one wheel 23 can have at least one notch 24 on its outer radius. The notch 24 prevents direct contact between the anvil 22 and the wheel 23 at this point.The connection between wheel 23 and the (covering) substrate 5 is interrupted, so that no ultrasonic welding takes place or an ultrasonic weld seam 29 is created at this point. Overall, in the embodiment just described, a regularly interrupted ultrasonic weld seam 29 is created.

[0029] In one embodiment, instead of a flat surface of the vibrating structure 21 on the opposite side of the ultrasonic welding device 20 (see figure 20), a surface of the vibrating structure 21 can be used. Fig. 2) the vibrating structure 21 has a contour 25 of the flat ribbon cable 1. The contour 25 essentially comprises recesses into which the conductors 2, 3 of the flat ribbon cable 1 are at least partially inserted. Ultrasonic welding preferably takes place on the raised areas between the recesses, i.e., the ultrasonic welds 29 are arranged there in this embodiment (see figure). Fig. 3) Contour 25 aids in the precise alignment of lines 2 and 3 before and during ultrasonic welding. Separate upstream guide rollers (as in prior art processes) are not necessary.

[0030] Furthermore, the in Fig. The device 10 shown in Figure 1 includes a feeding device 26 for feeding the base substrate 4, with at least the first and second conductors 2, 3 and the top substrate 5, to the ultrasonic welding device 20. The feeding device 26 can comprise a conveyor belt. In alternative embodiments, the workpieces to be welded can be drawn through the ultrasonic welding device 20, for example, by means of tension- or speed-controlled rollers or cylinders. Other feeding solutions are also possible. In the area of ​​the feeding device 26, the device 10 can further include a spraying device 28 for applying a foam 6 between the base substrate 4 and the top substrate 5. The applied foam 6 can serve as a dielectric and / or insulation for the flat ribbon conductor 1. Preferably, a PE dielectric is used as the foamed dielectric.Furthermore, the illustrated device 10 can have a fourth storage compartment 14 for providing a film 7, in particular a metallic film 7, between the base substrate 4 and the top substrate 5. In particular, the film 7 can first be arranged on the base substrate before conductors 2, 3 are placed on the base substrate 4, and after the conductors 2, 3 have been placed and foam 6 has been applied, another film 7 can be applied. In this configuration of the flat ribbon cable 1, the conductors 2, 3 receive an additional sheathing, or, in the case of a metallic film, shielding.

[0031] A preferred embodiment of a method for manufacturing a flat ribbon cable 1 is described below. The flat ribbon cable 1 has at least a first and a second conductor 2, 3. The method comprises at least the following steps: providing a base substrate 4 from a first storage location 11, wherein the base substrate 4 comprises a film-like plastic and extends in a ribbon-like manner along a first direction X. Providing at least the first and second conductors 2, 3 from a second storage location 12 and arranging the at least first and second conductors 2, 3 on the base substrate 4. The at least first and second conductors 2, 3 are arranged at a distance A from each other on the base substrate 4 and extend along the first direction X. Providing a cover substrate 5 from a third storage location 13, wherein the cover substrate 5 comprises a film-like plastic and extends in a ribbon-like manner along the first direction X.Arrange the top substrate 5 over the base substrate 4 such that at least the first and second conductors 2, 3 are positioned between the base substrate 4 and the top substrate 5. Finally, feed the base substrate 4, along with the at least first and second conductors 2, 3 and the top substrate 5, to an ultrasonic welding device 20. In the ultrasonic welding device 20, the base substrate 4 and the top substrate 5 are then joined by ultrasonic welding at least at a distance A between the at least first and second conductors 2, 3. The steps mentioned are preferably carried out in this order. The distance A is variable; it can differ between each pair of conductors 2, 3.In addition to ultrasonic welding at a distance A between conductors 2 and 3, ultrasonic welding can also be performed at the edges 30 of the ribbon cable 1 to seal the ribbon cable 1 at one or both edges 30 along the first direction X. Furthermore, so-called cut-and-seal processes are possible at the edge(s) 30, in which the edges 30 are ultrasonically welded and excess material of the base and cover substrate 4 and 5 is simultaneously removed.

[0032] In a further embodiment, the method can further include the following steps: folding the flat ribbon cable 1 at a bending edge K (see. Fig. 4) and ultrasonic welding of the folded flat ribbon cable 1 at new ultrasonic weld seams 29a, so that a multilayer flat ribbon cable 1a is formed. The folding at the fold edge K can be automated. Preferably, the flat ribbon cable 1 is folded in the middle, so that a first section T1 of the flat ribbon cable 1 and a second (folded) section T2 of the flat ribbon cable are of the same size. A multilayer flat ribbon cable 1a means that the cables 2, 3 are not only arranged next to each other in a second direction Y, but are also arranged next to or on top of each other in a third direction Z (see Figure 1). Fig. 5) For this embodiment or alternative embodiments, several ultrasonic welding devices 10 can be arranged appropriately (one behind the other or next to each other). REFERENCE MARK LIST 1 flat ribbon cable 1a multilayer flat ribbon cable 2 first line 3 second line 4 Base substrate 5 Top layer substrate 6 foam Slide 7 8 strands 9 coat 10 Device 11 first storage 12 second storage 13 third storage 14 fourth storage 20 ultrasonic welding devices 21 oscillating structures 22 Anvil 23 wheel 24 Notches 25 contour 26 Feeding device 28 Spray device 29 Ultrasonic welding 29a new ultrasonic weld 30 Rand A distance K bend edge T1 first sub-area T2 second sub-area V Vibration X first direction Y second direction Z third direction

Claims

[1] Method for manufacturing a flat ribbon cable (1) with at least a first and a second cable (2, 3), the method comprising the following steps: a) Providing a base substrate (4) from a first storage (11), wherein the base substrate (4) comprises a film-like plastic and extends in a ribbon-like manner along a first direction (X); b) Providing at least the first and second lines (2, 3) from a second storage (12) and arranging the at least first and second lines (2, 3) on the base substrate (4), wherein the at least first and second lines (2, 3) are arranged at a distance (A) from each other on the base substrate (4) and extend along the first direction (X); c) Providing a cover substrate (5) from a third storage (13), wherein the cover substrate (5) comprises a film-like plastic and extends in a ribbon-like manner along the first direction (X), and arranging the cover substrate (5) over the base substrate (4) such that at least the first and second conduits (2, 3) are arranged between the base substrate (4) and the cover substrate (5); and d) Feeding the base substrate (4) with the at least first and second lines (2, 3) and the top substrate (5) to an ultrasonic welding device (20) and joining the base substrate (4) with the top substrate (5) at least at the distance (A) between the at least first and second lines (2, 3) by ultrasonic welding. [2] Method according to claim 1, wherein the first and second lines (2, 3) comprise different line types. [3] Method according to claim 1 or 2, further comprising the steps: Folding of the flat ribbon cable (1) at a bending edge (K), and Ultrasonic welding of the bent flat ribbon cable (1) at new ultrasonic welds (29a) so that a multilayer flat ribbon cable (1a) is formed. [4] Device (10) for manufacturing a flat ribbon cable (1) with at least a first and a second cable (2, 3), wherein the device comprises at least: a) a first storage (11) for providing a base substrate (4), at least a second storage (12) for providing a first and a separate second line (2, 3) and a third storage (13) for providing a top substrate (5); b) an ultrasonic welding device (20) for ultrasonic welding of the base substrate (4) to the top substrate (5); and c) a feeding device (26) for feeding the base substrate (4) with at least the first and second lines (2, 3) and the top substrate (5) to the ultrasonic welding device (20). [5] Device according to claim 4, wherein the ultrasonic welding device (20) has at least one vibrating structure (21) and an anvil (22), and the ultrasonic welding process preferably takes place by a vibration (V) of the vibrating structure (21) directly between the vibrating structure (21) and the anvil (22). [6] Device according to claim 4 or 5, wherein the anvil (22) comprises a plurality of separate wheels (23) so that a continuous ultrasonic welding process can be carried out. [7] Device according to claim 6, wherein at least one wheel (23) has at least one notch (24) on the outer radius of the wheel (23) such that a regularly interrupted ultrasonic weld (29) is produced. [8] Device according to one of claims 4-7, wherein the vibrating structure (21) has a contour (25) of the flat ribbon cable (1). [9] Device according to one of claims 4-8, further comprising a spray device (28) for applying a foam (6) between the base substrate (4) and the top substrate (5). [10] Device according to one of claims 4-9, further comprising a fourth storage (14) for providing a film (7), in particular a metallic film (7), between the base substrate (4) and the top substrate (5).

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