Multilayer composite articles with integrated conductor arrangement

Abstract

The invention relates to a method (100) for manufacturing a multilayer composite article (10) with an integrated conductor arrangement (20). It is proposed to position a displacement body (30) on a carrier layer (12) of the multilayer composite article (10) on which the conductor arrangement (20) is positioned, such that when the cover layer (13) is applied to the carrier layer (12) in a predetermined layer thickness (a), a section of the cover layer (13) applied to the displacement body (30) is so thin that the position of the displacement body (30) in the multilayer composite article is haptically and / or visually discernible from the outside.

Description

[0001] The present invention relates to a method for manufacturing a multilayer composite article with an integrated conductor arrangement having the features of claim 1. The invention also relates to a multilayer composite article having the features of claim 8.

[0002] By integrating conductor arrangements into multilayer composite articles such as hoses, conveyor belts, belts and / or air springs, various advantageous functions of a sensory, signal-transmitting and / or actuator nature can be realized.

[0003] One problem here is the electrical contacting of the conductor arrangement embedded in the multilayer composite for signal transmission and / or power supply. This requires piercing an outer or cover layer of the composite and exposing a contact area of ​​the conductor arrangement in order to connect it electrically to an external component, such as a cable or connector. When piercing the outer layer and exposing the contact area, care must be taken to avoid damaging either the conductor arrangement or the rest of the multilayer composite. Furthermore, in many applications, the outer layer is opaque and relatively rigid, making the exact position of the conductor arrangement neither visually nor tactilely discernible.

[0004] The object of the present invention is to provide a method for manufacturing a multilayer composite article with an integrated conductor arrangement, which at least partially reduces the disadvantages of the prior art. In particular, a method is to be provided that simplifies the electrical contacting of the conductor arrangement embedded in the layered composite for the purpose of signal transmission and / or for the purpose of power supply.

[0005] This problem is solved by a method having the features of claim 1. Preferred features are the subject of the dependent claims. Further advantages and features can be found in the general description and the exemplary embodiments. The present invention also relates to a multilayer composite article having the features of claim 8.

[0006] The inventive method for producing a multilayer composite article, in particular a hose and / or a conveyor belt, containing an elastomeric material and preferably a reinforcing layer, with a conductor arrangement integrated in the multilayer composite article, comprises the following steps: - Providing a carrier layer for the multilayer composite article; - Arranging a ladder arrangement in a first area on the support layer; - Application, in particular extrusion, of a cover layer that at least partially covers the carrier layer and the conductor arrangement in a predetermined layer thickness.

[0007] The method according to the invention is characterized by the following step: - Providing or arranging a displacement body in the first area on the support layer, wherein the displacement body has a maximum thickness that is between 60% and 100% of the predetermined layer thickness, preferably between 80% and 100% of the predetermined layer thickness of the cover layer.

[0008] The invention is based on the idea of ​​selectively thinning the top layer at a clearly defined point in order to make the position of the conductor arrangement more easily identifiable and to facilitate penetration of the top layer for the purpose of electrical contacting the conductor arrangement. The thickness of the top layer is determined by the tools used to apply the top layer, such as an extrusion die or a doctor blade. The predetermined layer thickness can also be referred to as the nominal layer thickness or target layer thickness. The thickness of the top layer is defined, in particular, by the distance between an outer surface of the carrier layer and an inner surface of the tool used to apply the top layer. In hose production, for example, the thickness of the top layer is defined by the outer diameter of the carrier layer and the inner diameter of the extrusion die.

[0009] When components or structures of a specific thickness are applied to the substrate layer in a particular area, the true thickness of the top layer in that area may be less than the predetermined layer thickness. The conductor array, which, for example, might be printed onto a film-like substrate layer, typically has a much lower thickness than the top layer (e.g., less than 20% of the top layer thickness). Therefore, in the area of ​​the conductor array, the true thickness of the top layer does not deviate significantly from the predetermined thickness.

[0010] By providing or arranging a displacement body in the first region on the substrate layer, wherein the displacement body has a maximum thickness corresponding to between 60% and 100% of the layer thickness, preferably between 80% and 100% of the layer thickness of the cover layer, the true thickness of the cover layer is thinned to such an extent that the position of the displacement body, and thus indirectly or directly also of the conductor arrangement, is perceptible by touch and / or visually detectable from the outside. The displacement body can be arranged together with the conductor arrangement in the first region on the substrate layer or separately.

[0011] In some applications, particularly during extrusion, the coating layer applied to the displacement body may be peeled away by the inner surface of the tool used to apply the coating layer, thus exposing the displacement body. This facilitates, or ideally eliminates, a separate step for exposing the displacement body.

[0012] In particular, the conductor arrangement and, optionally, a substrate layer on which the conductor arrangement is arranged, have a thickness that is less than 30%, preferably less than 20%, and most preferably less than 10% of the predetermined thickness of the cover layer. Preferably, the thickness of the conductor arrangement (with or without the substrate layer) is 1 nm to 500 µm. Particularly preferably, the thickness of the conductor arrangement is 100 nm to 50 µm, so that the conductor arrangement can be reliably manufactured using established printing processes. The thickness of the conductor arrangement is defined here as the dimension of the conductor arrangement measured transversely to the layer plane or in the radial direction.

[0013] The elastomeric material is in particular an elastomer and / or a thermoplastic elastomer.

[0014] The multilayer composite article is, in particular, a hose whose layers extend essentially rotationally symmetrically around a longitudinal center axis, with the support layer enclosing a fluid channel for guiding a fluid. In this case, the support layer can be referred to as the inner layer and / or the cover layer as the outer layer. In this case, the support layer and the cover layer each form an essentially cylindrical shell. In this case, one direction along which thicknesses or heights are measured is the radial direction with respect to the longitudinal center axis.

[0015] The conductor arrangement can be printed electronics, meaning the conductive traces can be formed by conductive inks on a particularly flexible, dielectric substrate. The functions of the printed electronics can be, for example, sensory, signal-transmitting, and / or actuator-related. In other words, the conductor arrangement can form a sensor, an antenna, and / or an actuator, or a part thereof.

[0016] Preferably, the thickness of the carrier layer is 0.5 mm to 50 mm, more preferably 1 mm to 10 mm. Preferably, the thickness of the top layer is 0.5 mm to 50 mm, more preferably 1 mm to 10 mm.

[0017] In a preferred embodiment of the method according to the invention, the conductor arrangement and the displacement body are arranged on a common substrate layer, in particular printed on it. In this way, the conductor arrangement and the displacement body can be easily integrated together into the multilayer composite article. In addition, this defines a relative position between the conductor arrangement and the displacement body.

[0018] In a further preferred embodiment of the method according to the invention, the displacement body is made of an electrically conductive material. In this way, the displacement body can be located using electromagnetic sensors. Furthermore, the displacement body can interact with the conductor arrangement and, for example, itself provide the contact point. Preferably, the displacement body is electrically connected to the conductor arrangement. Preferably, the displacement body has a contact area configured to be electrically connected to an external component, in particular a connector and / or a cable. Alternatively, the displacement body can be a structure separate from the conductor arrangement, which is in particular spaced apart from the conductor arrangement and / or at least galvanically isolated.

[0019] In a further preferred embodiment of the method according to the invention, the method comprises the following steps: - Exposing at least part of the displacement body, in particular by removing a section of the cover layer covering the displacement body; and / or - Electrical contact of the displacement body and / or conductor assembly with an external component, in particular with a cable or a plug.

[0020] As described above and below, the problem set out at the beginning is also solved by a method with the features of claim 8.

[0021] The multilayer composite article according to the invention, in particular a hose and / or conveyor belt, comprises an elastomeric material and preferably a reinforcing layer. The multilayer composite article has a carrier layer and a conductor arrangement arranged on the carrier layer in a first region. The conductor arrangement and the carrier layer are at least partially covered by a cover layer of the multilayer composite article, which is applied to the carrier layer in a predetermined layer thickness or nominal thickness. The multilayer composite article is characterized by a displacement element arranged on the carrier layer in the first region, which has a maximum thickness that corresponds to between 60% and 100% of the predetermined layer thickness of the cover layer, preferably between 80% and 100% of the layer thickness of the cover layer.

[0022] In this way, the advantages described for the process are also realized in the multilayer composite article.

[0023] In a preferred embodiment of the multilayer composite article according to the invention, the conductor arrangement and the displacement body are arranged on a common substrate layer, in particular printed on it.

[0024] In a further preferred embodiment of the multilayer composite article according to the invention, the displacement body is made of an electrically conductive material.

[0025] In a further preferred embodiment of the multilayer composite article according to the invention, the displacement body is electrically connected to the conductor arrangement.

[0026] In a further preferred embodiment of the multilayer composite article according to the invention, the displacement body has a contacting area which is designed to be electrically connected to an external component, in particular to a plug and / or a cable.

[0027] In a further preferred embodiment of the multilayer composite article according to the invention, the displacement body is a structure separate from the conductor arrangement.

[0028] It is expressly pointed out that the embodiments of the invention described above can each be combined individually or in any technically meaningful combination with each other with the subject matter of the independent claims.

[0029] Variations and embodiments of the invention, as well as further advantages and details of the invention, can be found in the following description and the drawings. The schematic figures show: Fig. 1 an embodiment of a multilayer composite article according to the invention in a sectional view; Fig. 2 a flowchart of an exemplary embodiment of a method according to the invention.

[0030] Parts that have the same or similar effects are provided with identical reference numerals, if applicable.

[0031] Individual technical features of the embodiments described below can also be combined with previously described embodiments as well as the features of the independent claims and any further claims to create objects according to the invention.

[0032] Fig. Figure 1 shows an embodiment of a multilayer composite article 10 according to the invention, comprising a carrier layer 12 and a conductor arrangement 20 arranged in a first region 14 on the carrier layer 12. The multilayer composite article 10 further comprises a cover layer 13 applied to the carrier layer 12 in a predetermined layer thickness a. The cover layer 13 covers the conductor arrangement 20. The carrier layer 12 and / or the cover layer 13 contain an elastomer and / or a thermoplastic elastomer.

[0033] In the present case, the multilayer composite article 10 is designed as a tube whose layers 12, 13 extend rotationally symmetrically around a longitudinal central axis L. The height or thickness of a layer or body is measured in the radial direction R. The support layer 12 can also be referred to as the inner layer. The cover layer 13 can also be referred to as the outer layer. The support layer 12 has an innermost layer 18 that defines a fluid channel. The support layer 12 also has a metallic or textile reinforcing layer 11.

[0034] For the purpose of signal and / or power transmission, the conductor assembly 20 must be contacted with an external component, such as a cable or a connector. For this purpose, the cover layer 13 must be perforated in the first region 14, which covers the conductor assembly 20 and / or a substrate layer 40 on which the conductor assembly 20 is arranged. The conductor assembly 20 and the substrate layer 40, on which the conductor assembly 20 is arranged or printed, together have, for example, a thickness of 100 µm, which in many applications corresponds to or is less than 10% of the predetermined layer thickness a of the cover layer 13, ranging from 1 mm to 10 mm. If the cover layer 13 is, for example, designed as a black rubber layer, the position of the conductor assembly 20 in the multilayer composite article 10 cannot be detected from the outside, either by touch or with the naked eye.

[0035] Localization of the conductor arrangement 20 and penetration of the cover layer 13 are facilitated by the arrangement of a displacement body 30 in the first region 14 on the carrier layer 12. This displacement body has a maximum thickness b that is between 60% and 100% of the predetermined layer thickness a of the cover layer 13, preferably between 80% and 100% of the predetermined layer thickness a of the cover layer 13. The section 13a of the cover layer 13 located above the displacement body 30 has a much smaller layer thickness than the predetermined layer thickness a, so that the displacement body 30 can be detected from the outside by touch or sight. This also makes it easier to determine the position of the conductor arrangement 20.

[0036] The conductor arrangement 20 and the displacement body 30 are arranged on a common substrate layer 40, in particular printed on it, so that they can be arranged together on the carrier layer 12 during manufacturing.

[0037] In the present case, the displacement body 30 is a structure separate from the conductor arrangement 20. Alternatively, the displacement body 30 can be made of an electrically conductive material and be electrically connected to the conductor arrangement 20. The displacement body 30 can furthermore have a contact area 21 configured to be electrically connected to an external component, in particular a plug and / or a cable.

[0038] Fig.Figure 2 shows a flowchart of an embodiment of a method 100 according to the invention for producing a multilayer composite article 10, in particular a hose and / or a conveyor belt, containing an elastomeric material and preferably a reinforcing element, with a conductor arrangement 20 integrated in the multilayer composite article 10, wherein the method 100 comprises the following steps: - Providing 110 of a carrier layer 12 of the multilayer composite article 10; - Arranging 120 a ladder arrangement 20 in a first area 14 on the support layer 12; - Arranging 121 a displacement body 30 in the first region 14 on the support layer 12, wherein the displacement body 30 has a maximum thickness b which corresponds to between 60% and 100% of the predetermined layer thickness a of the cover layer 13, preferably between 80% and 100% of the layer thickness a of the cover layer 13; and - Applying 130, in particular extruding, a cover layer 13 covering at least partially the carrier layer 12 and the conductor arrangement 20 in a predetermined layer thickness a.

[0039] It is evident that steps 120 and 121 can be performed in reverse order or together.

[0040] Optionally, procedure 100 includes the following step: - Exposing 140 at least a part of the displacement body 30 by removing a section 13a of the cover layer 13 covering the displacement body 30.

[0041] Optionally, procedure 100 includes the following step: - Electrical contact 150 of the displacement body 30 with an external component, in particular with a cable or a plug.

[0042] It should also be noted that "showing" does not exclude any other elements or steps and "a" or "an" does not exclude a multitude.

[0043] The scope of protection of the present invention is defined by the patent claims and is not limited by the features explained in the description or shown in the figures.

Claims

[1] Method (100) for producing a multilayer composite article (10), in particular according to one of claims 8 to 13, in particular a hose and / or a conveyor belt, comprising an elastomeric material and preferably a reinforcing element, with a conductor arrangement (20) integrated in the multilayer composite article (10), comprising the following steps: - Providing (110) a carrier layer (12) of the multilayer composite article (10); - Arranging (120) a ladder arrangement (20) in a first area (14) on the support layer (12); - Applying (130), in particular extruding, a cover layer (13) at least partially covering the support layer (12) and the conductor arrangement (20) in a predetermined layer thickness (a); characterized by - Providing or arranging a displacement body (30) in the first area (14) on the support layer (12), wherein the displacement body (30) has a maximum thickness (b) that is between 60% and 100% of the predetermined layer thickness (a) of the cover layer (13). [2] Method (100) according to claim 1, wherein the conductor arrangement (20) and the displacement body (30) are arranged on a common substrate layer (40), in particular printed on it. [3] Method (100) according to claim 1 or 2, wherein the displacement body (30) is made of an electrically conductive material. [4] Method (100) according to claim 3, wherein the displacement body (30) is electrically connected to the conductor arrangement (20). [5] Method (100) according to claim 4, wherein the displacement body (30) has a contacting area (21) which is configured to be electrically connected to an external component, in particular to a plug and / or a cable. [6] Method (100) according to any one of claims 1 to 3, wherein the displacement body (30) is a structure separate from the conductor arrangement (20). [7] Method (100) according to any one of the preceding claims, comprising the following steps: - Exposing (140) at least part of the displacement body (30); and / or - Electrical contact (150) of the displacement body (30) and / or the conductor arrangement (20) with an external component, in particular with a cable or a plug. [8] Multilayer composite article (10), in particular hose and / or conveyor belt, comprising an elastomeric material and preferably a reinforcing element, with a conductor arrangement (20) integrated in the multilayer composite article (10), wherein the multilayer composite article comprises a carrier layer (12), a conductor arrangement (20) arranged in a first region (14) on the carrier layer (12) and a cover layer (13) which at least partially covers the conductor arrangement (20) and is applied in a predetermined layer thickness (a), characterized by a displacement body (30) arranged in the first area (14) on the carrier layer (12), which has a maximum thickness (b) that is between 60% and 100% of the predetermined layer thickness (a) of the cover layer (13). [9] Multilayer composite article (10) according to claim 8, wherein the conductor arrangement (20) and the displacement body (30) are arranged on a common substrate layer (40), in particular printed on it. [10] Multilayer composite article (10) according to claim 8 or 9, wherein the displacement body (30) is made of an electrically conductive material. [11] Multilayer composite article (10) according to claim 10, wherein the displacement body (30) is electrically connected to the conductor arrangement (20). [12] Multilayer composite article (10) according to claim 11, wherein the displacement body (30) has a contacting area (21) which is configured to be electrically connected to an external component, in particular to a plug and / or a cable. [13] Multilayer composite article (10) according to any one of claims 8 to 10, wherein the displacement body (30) is a structure separate from the conductor arrangement (20).

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