Flat ribbon cable for power and / or data transmission and method for manufacturing such a flat ribbon cable

Abstract

The present invention relates to a flat ribbon cable (10, 20, 30, 40, 50, 60) for power and / or data transmission comprising a flexible, ribbon-shaped insulating body (1) extending in a first plane (XY) along a longitudinal direction (X), a plurality of conductors (2) for power and / or data transmission running in the insulating body (1) along the longitudinal direction (X), and at least one cavity (4) extending alongside the plurality of conductors (2) in the insulating body (1), wherein the at least one cavity (4) can be filled with a pressurized gaseous or liquid medium, so that the shape of the cavity (4) changes and the stiffness of the flat ribbon cable (10) increases. The present invention further relates to a method for manufacturing a flat ribbon cable (10, 20, 30, 40, 50, 60) for power and / or data transmission with at least one cavity (4).

Description

Technical field

[0001] The invention relates to a flat ribbon cable for power and / or data transmission and a method for manufacturing a flat ribbon cable for power and / or data transmission, in particular for use in the automotive sector. State of the art

[0002] Flat ribbon cables, especially flexible flat ribbon cables and cable harnesses, for electrical power and / or data transmission are attracting increasing interest in the automotive sector due to their flexible properties and low weight. Their flexibility and pliability allow flat ribbon cables to conform well to the contours of a vehicle and be routed in a space-saving manner. However, this pliability means that the flat ribbon cable does not have a defined geometry, which complicates both automated and manual processing. Automation, however, is a crucial factor in the current and future automotive industry. Description of the invention

[0003] It is therefore an object of the present invention to provide a flat ribbon cable and a manufacturing method for such a cable that improves or simplifies automated further processing of the flat ribbon cable, in particular its assembly in a vehicle.

[0004] The aforementioned problem is solved by a flat ribbon cable according to claim 1 and a method for manufacturing a flat ribbon cable according to claim 8. Further advantageous embodiments of the invention can be found in the dependent claims, the description, and the drawings.

[0005] In particular, the above-mentioned problem is solved by a flat ribbon cable for power and / or data transmission, comprising a flexible, ribbon-shaped insulating body extending in a first plane along a longitudinal direction, a plurality of conductors for power and / or data transmission running along the longitudinal direction in the insulating body, and at least one cavity extending alongside the plurality of conductors in the insulating body, wherein the at least one cavity can be filled with a pressurized gaseous or liquid medium, so that the shape of the cavity changes and the stiffness of the flat ribbon cable increases.

[0006] This flat ribbon cable offers the advantage of being highly flexible, allowing for installation in various environments, such as vehicles, due to its inherent flexibility. Furthermore, its stiffness can be increased, at least temporarily, to facilitate automated processing / installation or to provide subsequent processes with a predetermined orientation and / or shape. Changing the cable's stiffness from flexible to rigid, with defined geometric positions, enables precise positioning for subsequent automation. This flat ribbon cable thus increases the degree of automation in processing and / or installing flat ribbon cables. Additionally, the unused cavity after assembly could potentially be used to insert repair strands.Filling with a pressurized medium includes gaseous or liquid media that are introduced into the cavity under overpressure, as well as liquid media that are introduced into the cavity without overpressure and preferably remain there, giving the cavity stiffness due to their density and / or incompressibility.

[0007] Preferably, the at least one cavity has at least two openings through which the pressurized gaseous or liquid medium can enter and exit the cavity. Preferably, the medium enters the cavity through a first opening and exits through a second opening. In effect, the medium is blown through the cavity, which, particularly with a gaseous medium, has the advantage of being easy to implement and pressurizing the cavity to a predetermined, constant pressure. This is especially useful when only a temporary increase in stiffness is required, for example, to grip a ribbon cable but then return it to a flexible position. In such cases, the cavity can be briefly purged with compressed air, increasing the stiffness to allow the ribbon cable to be gripped before the pressurized medium exits the cavity and the ribbon cable returns to its flexible state.

[0008] Preferably, the at least one cavity has only one opening through which the pressurized gaseous or liquid medium can enter the cavity. Since the cavity in this case forms a dead end, it can be filled with the medium, which then remains in the cavity. In this way, a higher pressure can be built up than by blowing the medium through the cavity.

[0009] Preferably, when filled with the pressurized medium, at least one cavity extends additionally in a third direction transverse to the first plane. This third-direction extension creates a three-dimensional volume with a pressure force to maintain its expansion, thereby hindering buckling in any of the three spatial directions and increasing the stiffness of the ribbon cable.

[0010] Preferably, at least one cavity is oriented longitudinally or transversely to the longitudinal direction. If the at least one cavity is oriented longitudinally, a single cavity may suffice to increase the stiffness of the entire ribbon cable. If the at least one cavity is oriented transversely to the longitudinal direction, several (preferably parallel) cavities are generally necessary, which in turn offer the advantage that the ribbon cable can be stiffened differently in different locations along its length.

[0011] Preferably, the at least one cavity has predetermined holes on at least one outer surface. These holes allow an adhesive to be introduced into the cavity and then spread through the holes along the cavity on one outer surface of the ribbon cable, so that the ribbon cable can be glued or at least fixed to a separate surface.

[0012] Preferably, the material of the insulating body, particularly in the region of the at least one cavity, exhibits high elasticity, or the material of the insulating body, particularly in the region of the at least one cavity, exhibits low elasticity. High or low elasticity refers to the cavity's ability to return to its original shape. In the case of high elasticity, the cavity returns completely to its original shape without the pressurized medium. In the case of low elasticity, the cavity does not (necessarily) return exactly to its original shape but remains in an undefined (collapsed) form.Returning to its original shape has the advantage that the original shape is known, meaning the ribbon cable returns to a known shape when the pressurized medium is removed. This is advantageous, for example, in automated further processing of the ribbon cable. The undefined shape can have the advantage that the insulating material swells but does not expand (and potentially contract), which can protect the material.

[0013] The aforementioned problem is further solved in particular by a method for manufacturing a flat ribbon cable for power and / or data transmission comprising at least one cavity, comprising the following steps: providing a first film extending in a first plane along a longitudinal direction, the first film forming a first part of the insulating body; applying a plurality of conductors to the first film; applying a second film to the first film such that the plurality of conductors are arranged between the first and the second film, the second film forming a second part of the insulating body; joining the first and second films to each other by means of heat and / or an adhesive at at least one joint point, so that the first and second films form an insulating body, and not joining the first and second films in the region of the at least one cavity.so that in this area the first and second sheets lie loosely against each other and can change their shape relative to each other.

[0014] The at least one cavity is, in particular, a separate cavity from the plurality of conductors in the insulating body. The insulating body, formed from at least the first and second films, comprises, in particular, a monolithic insulating body. The first and second films are joined to each other at at least one connection point, in particular permanently, by means of heat and / or an adhesive.

[0015] The first and second films exhibit flexible properties due to their material and thinness. Even when the first and second films are joined or connected to form an insulating body, the insulating body still exhibits flexible properties. These flexible properties can be used to lay the ribbon cable flexibly on a separate surface or contour. However, for automated installation of the ribbon cable, it can be advantageous to increase its stiffness, at least temporarily. This temporary increase in stiffness can be achieved by creating or forming a cavity within the ribbon cable. Since this cavity is created or arranged directly within the ribbon cable, no additional materials (besides the pressurized medium) are necessary to increase its stiffness.

[0016] Preferably, the method further comprises the step of introducing a liquid or gaseous medium under pressure into the at least one cavity, such that the at least one cavity changes its shape and the flat ribbon cable exhibits increased stiffness. The stiffness can be varied depending on the pressure and type of medium.

[0017] Preferably, the method further comprises the steps of: filling the at least one cavity with a cooling medium so that the ribbon cable can be used as a cooled ribbon cable for power and / or data transmission, or making holes on an outside of the at least one cavity and filling the at least one cavity with an adhesive so that the ribbon cable can be used as a self-adhesive ribbon cable for power and / or data transmission.

[0018] If at least one cavity of a ribbon cable is filled with a cooling medium, the cooling medium can be cooled during filling or cooled subsequently, and its heat storage capacity can provide extended cooling of the ribbon cable. Cooling can occur through (passive) heat exchange. Cooled electrical conductors can exhibit improved conductivity, thus producing positive effects on power and / or data transmission. Furthermore, passing cooling media through a cavity can ensure a safe operating temperature for the ribbon cable.

[0019] The adhesive, injected under pressure, can escape in small quantities through the holes in the cavity. If the ribbon cable is placed adhesive-side down against a separate surface, it will adhere to that surface. No additional fasteners besides the adhesive would be necessary. The escaping adhesive allows the ribbon cable to be flexibly attached to and / or along the cavity of the separate surface by simply pressing it down, either manually or automatically. Any remaining adhesive in the cavity could dry (after the ribbon cable has been laid and secured), resulting in a permanent increase in the cable's stiffness.

[0020] The following description of embodiments is given with reference to the accompanying figures. These show: Fig. 1 a first embodiment of a flat ribbon cable with a lateral cavity; Fig. 2 a second embodiment of the flat ribbon cable with a central cavity; Fig. 3 a third embodiment of the flat ribbon cable with two central cavities; Fig. 4 a fourth embodiment of the flat ribbon cable having at least two cavities oriented transversely to a longitudinal direction; Fig. 5 a fifth embodiment of the flat ribbon cable with a cavity of high elasticity; and Fig. 6 a sixth embodiment of the flat ribbon cable with a cavity of low elasticity.

[0021] Preferred embodiments are described in detail below with reference to the accompanying figures.

[0022] Fig. Figure 1 shows a first embodiment of a flat ribbon cable 10 for power and / or data transmission. The flat ribbon cable 10 shown has at least one flexible, ribbon-shaped insulating body 1 extending in a first plane XY along a longitudinal direction X. The material of the insulating body 1, particularly in the region (1a) of the at least one cavity 4, can have high elasticity, or the material of the insulating body 1, particularly in the region (1a) of the at least one cavity 4, can have low elasticity.

[0023] Within the depicted insulating body 1, a plurality of conductors 2 for current and / or data transmission run, wherein the conductors 2 run along the longitudinal direction X within the insulating body 1. The conductors 2 preferably comprise metallic conductors 2 for transmitting electrical current and / or electrical (data) signals. The plurality of conductors 2 comprises at least two conductors 2. The plurality of conductors 2 can be arranged in a single layer or in multiple layers along a third direction Z within the insulating body 1.

[0024] Furthermore, this includes in Fig. Figure 1 shows a flat ribbon cable 10 with at least one cavity 4 which extends, in addition to the plurality of conductors 2, into the insulating body 1. With regard to various embodiments of the flat ribbon cable 10, 20, 30, 40, 50, 60, the at least one cavity 4 can be arranged longitudinally (see Figure 1). Fig. 1, Fig. 2, Fig. 3, Fig. 5, Fig. 6) or across (see Fig. 4) be oriented to the longitudinal direction X. If the cavity 4 is oriented transversely to the longitudinal direction X, the ribbon cable 40 typically comprises a plurality of cavities 4. The plurality of cavities 4 can each be filled with different pressures and / or different types of medium. If at least one cavity 4 is oriented longitudinally to the longitudinal direction X, the cavity 4 can be oriented laterally to the conductors 2 (see figure). Fig. 1 and Fig. 5) and / or offset from the ladder plane (see Fig. 2, Fig. 3 and Fig. 6) arranged. In a further embodiment, the ribbon cable 30 has at least two cavities 4, 5 which are arranged at different positions on the ribbon cable 30. The second cavity 5 on the ribbon cable 30 can be created, for example, by applying a third film to the insulating body 1.

[0025] The at least one cavity 4 has predetermined holes 7 on at least one outer surface. The holes 7 or pores can be provided with a predetermined number and / or size. The number and size of the holes 7 can be adapted to the adhesive or the adhesive effect. Overall, the provision of holes 7 or pores in the at least one cavity 4 allows adhesive to flow out of the holes 7 or pores, thus distributing the adhesive evenly for securing the ribbon cable 20 in a (vehicle) body. After the ribbon cable 20 is attached, residual adhesive can remain in the cavity 4 to stiffen the shape of the ribbon cable 20 as defined by the body.

[0026] With reference to a synthesis of Fig. 1 and Fig. 5. The at least one cavity 4 can be filled with a pressurized gaseous or liquid medium, thus changing the shape of the cavity 4 and increasing the stiffness of the ribbon cable 10. The at least one cavity 4 can have at least two openings 6, 8 through which the pressurized gaseous or liquid medium can enter and exit the cavity 4. Alternatively, the at least one cavity 4 can have only one opening 6 through which the pressurized gaseous or liquid medium can enter the cavity 4. In this case, the cavity 4 would be closed at one end (opposite the first opening 6).

[0027] The following describes a preferred embodiment of a method for manufacturing a flat ribbon cable 10, 20, 30, 40, 50, 60 for power and / or data transmission with at least one cavity 4. The method comprises at least the following steps: providing a first film extending in a first plane XY along a longitudinal direction X, wherein the first film forms a first part of the insulating body 1. Preferably, a plurality of conductors 2 are then applied to the first film. The application of the conductor(s) 2 can be carried out using known methods. The conductors 2 can be, as in the Fig. 1-6 are shown, arranged in a single layer on the first slide or in multiple layers, i.e., as shown in the Fig. Figures 1-6 are shown, arranged along the third direction Z with insulating intermediate layers. Once the arrangement of the conductors 2 is complete, a second film is applied to the first film, so that the majority of the conductors 2 are arranged between the first and second films. The second film forms a second part of the insulating body 1. In alternative embodiments, the insulating body 1 can be composed of further parts, for example, to form a second or further cavities 5. In the third embodiment of the flat ribbon cable 30, which is shown in Fig. As shown in Figure 3, a second cavity 5 can, for example, be created on the side of the ribbon cable 30 opposite the first cavity 4 by means of another film. The first and second (and possibly further) films are then joined together at at least one connection point 3 using heat and / or an adhesive, so that the first and second (and possibly further) films form an insulating body 1. There are known methods for joining the films. In addition to joining the films together at the at least one connection point 3, particularly in the area of ​​the conductors 2, the first and second films are simultaneously left unattached in the area of ​​the at least one cavity 4, so that in this area the first and second films lie loosely against each other and can change their shape relative to one another.

[0028] If the flat ribbon cable 10, 20, 30, 40, 50, 60 has been manufactured according to the preceding process steps, its stiffness can be increased by introducing a liquid or gaseous medium under pressure into the at least one cavity 4, causing the cavity 4 to change its shape and resulting in increased stiffness for the flat ribbon cable 10, 20, 30, 40. In particular, the resulting height (in the third direction Z) increases the Steiner coefficient and thus, in turn, the stiffness of the flat ribbon cable 10. This increase in stiffness makes a flexible flat ribbon cable 10 dimensionally stable and allows for precise positioning, for example, in a vehicle.

[0029] In practice, this means that in a preferred embodiment, a nozzle is inserted at or into the first opening 6 of a cavity 4, and the pressurized medium is filled into the cavity 4 via the nozzle. The filling of the medium changes the initial shape of the cavity 4 (see figure). Fig. 5 and Fig. 6) towards an erected cavity 4 (see Fig. 1, Fig. 2, Fig. 3 to Fig.4) In particular, "formed" means that the cavity 4, in addition to extending in the first plane XY, also extends in the third direction Z, thereby increasing the stiffness of the entire ribbon cable 10, 20, 30, 40. If no more medium is dispensed from the nozzle and the cavity 4 has at least two openings, the cavity 4 will return to its original shape (after the medium exits the second opening 8), depending on the elasticity of the cavity material. If the cavity 4 has only a first opening 6, it can happen, as in the case of an injected adhesive, that the medium, or at least a part of it, remains in the cavity 4 after filling stops, leading to a permanent deformation of the cavity 4 and an increase in the stiffness of the ribbon cable 10, 20, 30, 40.The adhesive used to join the films can be the same adhesive used to attach the ribbon cable 20, as it has at least good adhesion to / on the film.

[0030] If adhesive is introduced as a medium into the cavity 4, the adhesive is intended to serve as an adhesive for the ribbon cable 20. In this case, a preferred embodiment comprises the following steps: holes 7 are introduced into an outer surface of the at least one cavity 4, and the at least one cavity 4 is filled with an adhesive, so that the ribbon cable 20 can be used as a self-adhesive ribbon cable for power and / or data transmission. The holes 7 or pores are many times smaller than the first and / or second opening 6, 8, so that only very small amounts of adhesive emerge from each hole 7 simultaneously, and the cavity 4 can act as a reservoir for the adhesive in the ribbon cable 20. The introduction of the holes 7 or pores can take place during the manufacture of the film or subsequently, after the insulating body 1 has been produced. The introduction of the holes 7 or pores can be carried out using known mechanical and / or laser methods.The pressurized adhesive emerges evenly from the cavity 4 through the holes 7 or pores and forms an adhesive surface on the outside of the ribbon cable 20. The ribbon cable 20 can be easily and quickly attached or fixed to a separate surface, such as a vehicle body, via this adhesive surface, which preferably extends along the entire cavity 4 or cavities 4.

[0031] In addition to filling a cavity 4 with an adhesive, an alternative process step can be carried out, namely filling the at least one cavity 4 with a cooling medium, so that the ribbon cable 10 can be used as a cooled ribbon cable 10 for power and / or data transmission. The cooling medium can comprise water, gel, oil, or another (liquid) medium suitable for cooling. If the first (and, if present, also the second) opening 6 (8) is closed after filling the cavity 4, the cooling medium remains in the ribbon cable 10 and can provide continuous cooling of the ribbon cable 10. With regard to the third embodiment, which has a first and second cavity 4, 5, for example, the first cavity 4 of the ribbon cable 30 can be filled with an adhesive and the second cavity 5 with a cooling medium.

[0032] In addition to permanently filling at least one cavity 4 with adhesive or coolant, at least one cavity 4 can also be left empty, so that it can be used, for example, for the possible insertion of repair strands after assembly. REFERENCE MARK LIST 1 Insulating body 1a Area of ​​the cavity 2 conductors 3 Connection point 4 cavities 5 second cavity 6 first opening 7 holes 8 second opening 10 flat ribbon cables (first embodiment) 20 flat ribbon cables (second embodiment) 30 flat ribbon cables (third embodiment) 40 flat ribbon cables (fourth embodiment) 50 flat ribbon cables (fifth embodiment) 60 flat ribbon cables (sixth embodiment) X Longitudinal direction XY first level Y second direction Z third direction

Claims

Flat ribbon cable (10, 20, 30, 40, 50, 60) for power and / or data transmission comprising: a) a flexible, ribbon-shaped insulating body (1) extending in a first plane (XY) along a longitudinal direction (X); b) a plurality of conductors (2) for power and / or data transmission running in the insulating body (1) along the longitudinal direction (X); and c) at least one cavity (4) extending alongside the plurality of conductors (2) in the insulating body (1); wherein d) the at least one cavity (4) can be filled with a pressurized gaseous or liquid medium, such that the shape of the cavity (4) changes and the stiffness of the flat ribbon cable (10) increases. Flat ribbon cable according to claim 1, wherein the at least one cavity (4) has at least two openings (6, 8) through which the pressurized gaseous or liquid medium can enter and exit the cavity (4). Flat ribbon cable according to claim 1, wherein the at least one cavity (4) has only one opening (6) through which the pressurized gaseous or liquid medium can enter the cavity (4). Flat ribbon cable according to one of claims 1 - 3, wherein the at least one cavity (4), when filled with the pressurized medium, additionally extends in a third direction (Z) transversely to the first plane (XY). Flat ribbon cable according to one of claims 1 - 4, wherein the at least one cavity (4) is oriented longitudinally or transversely to the longitudinal direction (X). Flat ribbon cable according to one of claims 1 - 5, wherein the at least one cavity (4) has predetermined holes (7) on at least one outer side. Flat ribbon cable according to one of claims 1 - 6, wherein the material of the insulating body (1), in particular in the region (1a) of the at least one cavity (4), has a high elasticity, or wherein the material of the insulating body (1), in particular in the region (1a) of the at least one cavity (4), has a low elasticity. A method for manufacturing a flat ribbon cable (10, 20, 30, 40, 50, 60) for power and / or data transmission, comprising at least one cavity (4) and the following steps: a) providing a first film extending in a first plane (XY) along a longitudinal direction (X), the first film forming a first part of the insulating body (1); b) applying a plurality of conductors (2) to the first film; c) applying a second film to the first film such that the plurality of conductors (2) are arranged between the first and second films, the second film forming a second part of the insulating body (1); d) joining the first and second films to each other by means of heat and / or an adhesive at at least one joint (3), such that the first and second films form an insulating body (1);ande) not fixing the first and second foils in the area (1a) of the at least one cavity (4), so that in this area (1a) the first and second foils lie loosely against each other and can change their shape relative to each other.; Method according to claim 8, further comprising the step: introducing a liquid or gaseous medium under pressure into the at least one cavity (4), such that the at least one cavity (4) changes its shape and the flat ribbon cable (10) has increased stiffness. The method of claim 8 or 9, further comprising the steps of: filling the at least one cavity (4) with a cooling medium, so that the ribbon cable (10) can be used as a cooled ribbon cable (10) for power and / or data transmission; or providing holes (7) on an outside of the at least one cavity (4) and filling the at least one cavity (4) with an adhesive, so that the ribbon cable (20) can be used as a self-adhesive ribbon cable (20) for power and / or data transmission.

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