Method for manufacturing a transport means with a substrate and a conductor structure

Abstract

The present intellectual property right relates to a means of transport and a method for manufacturing a means of transport (1), in particular a drone. The method for manufacturing a means of transport (1) is characterized by the following process steps: Formation of a deep-drawable substrate (11a) with a conductor structure that is at least partially flexible, Deep drawing of the substrate together with the conductor structure into a shaped body (11b), wherein the deep drawing in the shaped body forms receiving devices (13, 15) for one or more motors and / or one or more energy storage elements and / or electronic components (16, 17), Insertion of one or more motors and / or one or more energy storage elements and / or electronic components into the receiving facilities of the molded body formed by deep drawing, as well as Contacting the motor(s) and / or energy storage elements and / or electronic components with elements of the conductor structure.

Description

[0001] For the autonomous monitoring of facilities such as high-voltage power lines, autonomously moving transport vehicles like unmanned aerial vehicles (drones) are increasingly being used. These aircraft carry sensors and communication units to transmit sensor data such as camera images and receive control information. The aircraft also require motors, energy storage elements, and a control system. The production of such autonomous transport vehicles is still complex and expensive due to the high reliability and fail-safe operation required under the high and variable loads to which they are subjected.

[0002] Therefore, various efforts are being made to both save on components and simplify manufacturing. In many cases, the aim is to find a compromise between lightweight construction, stability, and flexibility.

[0003] In principle, technical possibilities already exist for arranging electronic components on flexible substrates and integrating conductor tracks into such substrates.

[0004] Such flexible components are already known, for example, from patent document WO 2011 / 000580 A1 and from EP 1926 355 B1.

[0005] Document US 2012 / 0056041A1 discloses a flying drone with frame parts and drive units mounted on them, the frame parts being designed as printed circuit boards.

[0006] Document CN 1 17 885 932 A describes a drone with minimized energy consumption, whose fuselage is partly made of a lyre board and which is partly powered by energy obtained from a solar cell.

[0007] Document US 2010 / 0120273 A1 describes a flying drone in which a circuit board forms part of the flying body.

[0008] From publication US 2017 / 0088205 A1, a robot with several rigid printed circuit boards is known, which are connected via a printed circuit board section that can be folded by means of an actuator.

[0009] In light of the prior art, the present invention aims to create a simplified method for manufacturing transport vehicles that are robust and reliable.

[0010] The problem is solved using the features of the independent claims. The dependent claims present possible implementations of the invention.

[0011] The invention thus relates to a method for manufacturing a means of transport, in particular a flying drone, with one or more motors, in particular electric motors, and an energy storage unit as well as an electronic control unit, comprising the following method steps: Formation of a deep-drawable substrate with a conductor structure that is at least partially flexible, Deep drawing of the substrate together with the conductor structure into a molded body, wherein the deep drawing in the molded body forms receiving devices for one or more motors and / or one or more energy storage elements and / or electronic components, insertion of one or more motors and / or one or more energy storage elements and / or electronic components into the receiving devices of the molded body formed by the deep drawing, and contacting of the motor(s) and / or energy storage elements and / or electronic components with elements, in particular contacts, of the conductor structure.

[0012] Deep drawing the substrate together with the conductor structure creates a shaped body that can have any desired form, for example, one that meets the required mechanical stability criteria for the transport vehicle. Such shapes often feature U-profiles, profiles curved in one or more directions, or L-profiles, which achieve extremely high stability at a low weight. Simultaneously, the resulting three-dimensional shaped body can be provided with a conductor structure in any desired area of ​​its surface. After deep drawing, such areas may be so difficult to access that conductor structures could hardly be positioned at that point. Alternatively, a film carrying a conductor structure can be bonded to the deep-drawable substrate, thereby mechanically stabilizing it and giving it its strength.In many cases, thermoformable substrates have plastic layers with softening temperatures below 100°C or even below 90°C, at which the thermoforming process can take place. Materials such as PMMA (polymethyl methacrylate) or polycarbonates, as well as other plastics, can be used for these substrates. In some cases, the substrate can be heated only in certain areas for thermoforming. The thermoforming process can be carried out, for example, at temperatures below 200°C, particularly below 180°C. Many semiconductor or electronic components can withstand these temperatures, so that at least some electronic components can be mounted on the substrate before thermoforming.

[0013] The conductor structures can be formed by conductive tracks, which may, for example, be arranged as a film on a plastic substrate. The conductive tracks can run in a zigzag, meandering, or wave-like pattern, at least in certain areas, along a main direction of extension to ensure the desired deformability during deep drawing. More generally, the conductive tracks can exhibit alternating changes of direction in two or three dimensions along a main direction of extension. The resulting body formed during deep drawing may, for example, have strongly curved or bent areas with radii of curvature of less than 3 mm, particularly less than 1 mm, and in some cases, conductive structures may also be incorporated within these radii of curvature.The molded body can also have elastically deflectable tongues, or tongues that are less elastically deflectable or inelastically deflectable at film hinges, which can be used to position or clamp motors, energy storage elements, or circuit carriers. These tongues can also be covered with conductor structures, so that conductor tracks also run across film hinges or kinks in the substrate.

[0014] An advantageous embodiment may provide that at least one circuit carrier with electronic components is applied to the deep-drawable substrate before or after deep drawing.

[0015] Another advantageous embodiment can provide that the circuit carrier is contacted with contacts of the conductor structure before or after deep drawing.

[0016] If a circuit carrier with electronic components, such as semiconductor elements, is applied to the thermoformable substrate after thermoforming, the electronic components do not need to be taken into account during the thermoforming process, and a recess for the circuit carrier can be formed in the molded body. The circuit carrier, which may contain, for example, a control unit for the transport device, can be inserted or clamped into this recess, and a locking mechanism for securing the circuit carrier can also be provided. Additionally, the circuit carrier can be bonded to the molded body with an adhesive. The adhesive can be added during assembly or it can be applied to the molded body and activated after the circuit carrier is inserted, for example, by pressure, temperature increase, or irradiation.

[0017] If a circuit carrier with electronic components, for example semiconductor elements, is applied to the deep-drawable substrate before deep drawing, the area of ​​the circuit carrier can be excluded from the deep-drawing mold, for example.

[0018] Connections and, in some cases, contacts between the circuit carrier and the molded body can be stabilized, for example, during the temperature increase in deep drawing, by temporarily melting connecting materials or contacting materials.

[0019] It can also be provided that, by inserting the motor(s) and / or energy storage elements and / or electronic components into the receiving devices of the molded body, an electrical connection to contacts of the conductor structure is automatically established. Deep drawing allows for the formation of resilient receptacles for the motor(s) and / or energy storage elements and / or electronic components on the molded body, which are also equipped with conductor structures and electrical contacts, enabling the elements inserted into the receptacles to be resiliently contacted. The contacts can be secured or reinforced by soldered connections or electrically conductive adhesive bonds.

[0020] It may also be provided that mechanical locking devices or precursors of locking devices for fixing one or more motors and / or one or more energy storage elements and / or electronic components are formed by deep drawing.

[0021] Deep drawing can, for example, create recessed, cut-out, or breakable tabs in a specific area of ​​the molded part. These tabs can be deflected, for instance, by 90 degrees from a plane of the molded part and generate a restoring force that allows a motor or other component to be clamped in place. The tabs can be cut out before or after deep drawing, or the deep drawing process can create predetermined breaking points for easy removal of the tabs.

[0022] The tongues may have retaining elements in the form of hooks or shoulders that lock into place when motors or other elements are inserted into the corresponding receptacle.

[0023] Another advantageous embodiment may provide that spring-loaded contacts for electrical contacting of elements of the conductor structure with one or more motors and / or one or more energy storage elements and / or electronic components are formed by deep drawing.

[0024] The contacts are formed as elements of the conductor structure on the deep-drawable substrate and later on the molded body.

[0025] It may also be provided that one or more reinforcing elements are arranged at least in certain areas on the deep-drawable substrate or in the deep-drawing mold before deep drawing.

[0026] Such reinforcing elements can be formed by metal inserts or fibrous materials that are connected, glued or fused to the molded body during the deep drawing process.

[0027] Another advantageous embodiment can provide that, during deep drawing, predetermined breaking points and / or film hinges of the molded body are formed by thinning the deep-drawable substrate in certain areas, and that after deep drawing the predetermined breaking points are broken and / or film hinges are bent.

[0028] It may also be provided that, after deep drawing, areas are cut out of the molded body using a subtractive process, in particular laser or water jet cutting.

[0029] In some cases, such a subtractive process can also be used alternatively or additionally before deep drawing to cut away parts of the substrate that are no longer easily accessible after deep drawing.

[0030] Therefore, in one implementation, it may be provided that cutouts are made in the deep-drawable substrate before deep drawing.

[0031] Another advantageous embodiment may provide that the deep drawing takes place at temperatures below 180 degrees Celsius, in particular between 80 degrees Celsius and 180 degrees Celsius.

[0032] As explained above, this makes deep drawing possible for many possible substrate materials without damaging electronic components that are already connected to the deep-drawable substrate.

[0033] Furthermore, as already indicated above, it may be provided that after insertion into the receiving devices of the molded body, one or more motors and / or one or more energy storage elements and / or electronic components are bonded to the molded body.

[0034] A further advantageous embodiment may provide that, after insertion into the receiving devices of the molded body, one or more motors and / or one or more energy storage elements and / or electronic components are electrically contacted with elements of the conductor structure of the molded body by means of a solder material and / or a conductive adhesive, or that existing contacts are secured by means of a solder material and / or a conductive adhesive.

[0035] It is also possible in one implementation to apply electronic components to the deep-drawable substrate before deep drawing and to electrically connect these components to elements of the conductor structure.

[0036] Such electronic components can, for example, be directly connected and contacted with the conductor structure of the deep-drawable substrate even before deep drawing. Alternatively, they can first be mounted on a circuit carrier in the form of a circuit board, which in many cases can be flexible or deformable under heat, and then connected to the substrate.

[0037] Ultimately, it may also be provided that one or more recesses of the molded body are at least partially filled with a rigid foam.

[0038] Such foaming can further stabilize the molded body mechanically and protect the functional elements such as motors, energy storage elements, or a control device intended for the means of transport.

[0039] A payload in the form of fillable elements, bulk material, or a body, particularly a deformable body, can also be placed and enclosed within the cavities of the molded body. In particular, an explosive can also be introduced into such cavities, or the cavities can be filled with an explosive. A plastic or metal film, stretched over the fillable cavities and / or recesses of the molded body, can be used to enclose the payload.

[0040] The invention relates not only to a method of the type mentioned above, but also to a means of transport, in particular a flying drone, with one or more motors, in particular electric motors, and an energy storage unit as well as an electronic control unit and a shaped body which carries the aforementioned elements and is designed as a deep-drawn body with a conductor structure applied before deep drawing.

[0041] The invention is shown below with reference to exemplary embodiments in figures of a drawing and then described.

[0042] This shows: Fig. 1: in a perspective drawing, a deep-drawn shape, Fig. 2: a shaped body equipped with motors, energy storage elements and a control unit in a top view from below, Fig. 3: a schematic sectional view along line III-III, as shown in the Fig. 2 displayed, Fig. 4: a schematic sectional view along line IV-IV, as shown in the Fig. 2 displayed, Fig. 5: a schematic sectional view along line VV, as shown in the Fig. 2 displayed, Fig. 6: A view of the molded body with elements of a ladder structure drawn in, Fig. 7: a cross-section through a deep-drawable substrate with a ladder structure, as well as Fig. 8: Three examples of ladder shapes with changing directions.

[0043] Fig. Figure 1 shows a perspective view of a deep-drawn body 11b, which has four arms 22, 23, 24, 25 connected to each other in a central area of ​​the body. Each arm is approximately a U-shaped or parabolic hollow profile and is deep-drawn from a flat, deep-drawable substrate 11a. The deep-drawable substrate already exhibits elements of a ladder structure before deep-drawing, which will be described below. At the free end of each of the arms 22, 23, 24, 25, a receptacle for an electric motor is formed, allowing motors to be used to drive propellers and form a flying drone.

[0044] The Fig. Figure 2 shows a drone in the position it assumes during flight, viewed from below. Motors 2, 3, 4, and 5 are inserted into the mounts 13 at the ends of the arms of the molded body 11b. The mounts are designed as pincer-like clamps that partially grip the motors. The clamps of the mounts can be designed and adapted to the size of the motors so that they expand slightly elastically when the motors are inserted, thus clamping the motors in place with a spring-like action. Electrical contacts can be provided on the inner surfaces of the clamps, which connect to corresponding electrical contacts on the motors. To secure the electrical contacts and the mechanical fastening, the motors and their electrical contacts can also be bonded to the molded body using an adhesive.

[0045] Four energy storage elements 6, 7, 8, 9 are shown in the hollow profile of the molded body. These elements can, for example, be designed as electrical, rechargeable batteries. Each energy storage element 6 is clamped in a receptacle formed by two tongues 14a, 14b, which are bent at right angles from the base material of the molded body. During the manufacture of the molded body, the tongues can be cut out before or after the deep-drawing process. A film hinge 19 can be formed during the deep-drawing process or by a clamping method to facilitate the bending of the tongue. This hinge is shown in more detail in the following section. Fig. 3 is shown.

[0046] In the central area 26 of the molded body, a control unit 10 is shown, which can have a circuit carrier 10a and electronic components 16, 17. The circuit carrier 10a can also be, as in the Fig. 3 is shown in a photograph of the shaped body 11b between bent tongues 15 of the substrate.

[0047] Other forms of incorporation are also conceivable, such as cavities or recesses provided in the molded body into which the energy storage elements or a control unit can be inserted.

[0048] The Fig. Figure 3 shows in detail, using an example, how recesses for the energy storage elements, the motors and a control unit can be formed in the molded body.

[0049] The shaped body 11b is in a cross-section along the in the Fig. 2 shown with line labeled III-III. Within the hollow profile of the molded body, which is in the Fig. 4 and Fig. As shown in another cross-section in Figure 5, an energy storage element 6 is clamped between two tongues 14a, 14b. The tongues 14a, 14b are cut free in the thermoformable substrate and, after thermoforming, bent out of the plane of the substrate by 90 degrees in the direction of arrows 14c, 14d. They hold the energy storage element 6 in a resilient manner. The tongue 15, which forms part of a receptacle for the circuit carrier 10a, is bent in a similar shape. The circuit carrier 10a carries electronic components 16, 17 and forms a control unit 10. The entire control unit 10 can also be referred to as an electronic component. The base of the tongues 14a is shown by way of example to indicate that the point where the tongue is bent out of the substrate can be weakened and / or thinned to form a film hinge, define the bending point, and facilitate bending.

[0050] On the right side of the Fig. Figure 3 shows a motor 2 clamped between clamps 13a of a motor mount. To ensure even more secure mounting of the motors, a hollow cylindrical shape can also be formed within the mold body to accommodate the motors.

[0051] Electrical contacts can be formed on the inner surfaces of the tongues 14a, 14b, 15 and the clamps 13a, 13b of the receptacles 13. These contacts form part of the conductor structure on the thermoformable substrate 11a, 11b or are connected to it. After the energy storage elements, motors, and control unit are inserted, these contacts can electrically connect them. To secure the electrical contact, the contact points can be additionally bonded with an adhesive and / or solder. An adhesive that can be activated by heat, pressure, or radiation can be applied to the substrate prior to assembly.

[0052] The Fig. Figure 4 shows the hollow profile of the molded body 11b in a cross-sectional view, as in the Fig. 2 indicated along line IV-IV, where the energy storage element 6 and the tongue 14a can be seen.

[0053] In the Fig. Figure 5 shows the hollow profile of the molded body 11b in a cross-sectional view, as in the Fig. 2 is indicated along line VV, showing a foam filling 20 of the cavity of the hollow profile. The foam filling can be sealed on its underside by a film, for example a metal film 27.

[0054] Instead of foam filling solely for stabilization and stiffening, a payload can also be incorporated. Alternatively or additionally, the molded body can also have a separate receptacle for a payload.

[0055] In the Fig. Figure 6 shows a shaped body 11b in a view from the underside, with the energy storage elements 6, 7, 8, 9 and motors 2 and their mounts 13, 14, 15 at least schematically indicated. In contrast to the structure according to the Fig. 2 The control unit is formed by electronic elements 16, 17, which are arranged directly on the thermoformable substrate prior to thermoforming and are contacted by conductor tracks 28, 29, each of which forms elements of the conductor structure 12. This structure is arranged on the thermoformable substrate and is deformed together with it during the thermoforming process. The electronic components 16, 17 can, for example, be excluded from the thermoforming die so that they are not subjected to mechanical stress during the thermoforming process.

[0056] Conductive traces 30, 31 are also shown, which connect the energy storage elements 6 and the motors to the control unit. The conductive traces can extend over the surfaces of the bendable tongues 14a, 14b, 15 or the clamps 13a of the motor mounts and form contact surfaces there for pressure contacting these elements.

[0057] The Fig. Figure 7 shows schematically in a side view the deep-drawable, flat substrate 11a and the conductor structure 12 on it, for example in the form of a metal cladding, in particular copper cladding.

[0058] The conductor tracks can each be individually formed in alternating curved or bent directions, for example in zigzag or meander shapes, to ensure optimal deformability during deep drawing.

[0059] The Fig.Figure 8 shows three exemplary conductor shapes with regularly changing directions: a meander shape (designated 31), a zigzag or sawtooth shape (designated 32), and a wavy shape (designated 33). Such changes in direction can be implemented in one plane or in all three dimensions to optimize the conductor's flexibility.

[0060] The main / longitudinal direction of all three conductor tracks is indicated by arrow 34.

Claims

[1] Method for manufacturing a means of transport (1), in particular a flying drone, with one or more motors (2, 3, 4, 5), in particular electric motors, and an energy storage unit (6, 7, 8, 9) and an electronic control unit (10), characterized by the following procedural steps: Formation of a deep-drawable substrate (11a) with a conductor structure (12) that is at least partially flexible, Deep drawing of the substrate together with the conductor structure into a shaped body (11b), wherein the deep drawing in the shaped body forms receiving devices (13, 14, 15) for one or more motors and / or one or more energy storage elements and / or electronic components (16, 17), Insertion of one or more motors and / or one or more energy storage elements and / or electronic components into the receiving facilities of the molded body formed by deep drawing, as well as Contacting the motor(s) and / or energy storage elements and / or electronic components with elements, in particular contacts (18, 19), of the conductor structure. [2] Method according to claim 1, characterized by , that at least one circuit carrier (10a) with electronic components (16, 17) is applied to the deep-drawable substrate (11a) before or after deep drawing. [3] Method according to claim 2, characterized by , that the circuit carrier (10a) is contacted with contacts of the conductor structure (12) before or after deep drawing. [4] Method according to any one of claims 1 to 3, characterized by , that by inserting the motor(s) (2, 3, 4, 5) and / or the energy storage elements (6, 7, 8, 9) and / or the electronic components (16, 17) into the receiving devices (13, 14, 15) of the molded body (11b) an electrical connection to contacts of the conductor structure (12) is automatically established. [5] Method according to any one of claims 1 to 4, characterized by , that by deep drawing mechanical locking devices or precursors of locking devices for fixing one or more motors (2, 3, 4, 5) and / or one or more energy storage elements (6, 7, 8, 9) and / or electronic components (16, 17) are formed. [6] Method according to any one of claims 1 to 5, characterized by , that spring contacts (18, 19) are formed by deep drawing for electrical contacting elements of the conductor structure (12) with one or more motors (2, 3, 4, 5) and / or one or more energy storage elements (6, 7, 8, 9) and / or electronic components (16, 17). [7] Method according to any one of claims 1 to 6, characterized by , that before deep drawing, at least in certain areas one or more reinforcing elements (18) are arranged on the deep-drawable substrate (11a) or in the deep-drawing mold. [8] Method according to any one of claims 1 to 7, characterized by , that during deep drawing, predetermined breaking points and / or film hinges (19) of the shaped body (11b) are formed by thinning the deep-drawable substrate in certain areas, and that after deep drawing the predetermined breaking points are broken and / or film hinges are bent. [9] Method according to any one of claims 1 to 8, characterized by , that after deep drawing, areas are cut out of the molded body using a subtractive process, in particular laser or water jet cutting. [10] Method according to any one of claims 1 to 9, characterized by , that cutouts are made in the deep-drawable substrate (11a) before deep drawing. [11] Method according to any one of claims 1 to 10, characterized by that deep drawing takes place at temperatures below 180 degrees Celsius, especially between 80 degrees Celsius and 180 degrees Celsius. [12] Method according to any one of claims 1 to 11, characterized by , that after insertion into the receiving devices (13, 14, 15) of the molded body (11b) one or more motors (2, 3, 4, 5) and / or one or more energy storage elements (6, 7, 8, 9) and / or electronic components (16, 17) are bonded to the molded body (11b). [13] Method according to any one of claims 1 to 12, characterized by , that after insertion into the receiving devices (13, 14, 15) of the molded body (11b) one or more motors (2, 3, 4, 5) and / or one or more energy storage elements (6, 7, 8, 9) and / or electronic components (16, 17) are electrically contacted with elements of the conductor structure (12) of the molded body by means of a solder material and / or a conductive adhesive or existing contacts are secured by means of a solder material and / or a conductive adhesive. [14] Method according to any one of claims 1 to 13, characterized by, that electronic components (16, 17) are applied to the deep-drawable substrate (11a) before deep drawing and these are electrically connected to elements of the conductor structure (12) and / or that one or more recesses of the molded body (11b) are at least partially filled with a rigid foam (20). [15] Means of transport (1), in particular a flying drone, with one or more motors (2, 3, 4, 5), in particular electric motors, and an energy storage unit (6, 7, 8, 9) as well as an electronic control unit, characterized by a shaped body that carries the aforementioned elements and is designed as a deep-drawn body with a ladder structure applied before deep drawing.

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