METHOD FOR PRODUCE A COMPONENT EQUIPPED WITH AT LEAST ONE ELECTRICALLY CONDUCTIVE CONDUCTOR

Description

[0001] The invention relates to a method for producing a component provided with at least one electrically conductive conductor body, wherein the conductor body is surrounded at least in sections in a material-locking and / or form-locking manner by an injection-molded body formed from an injection-molded material.

[0002] Corresponding methods for producing a component provided with at least one electrically conductive conductor body are known in principle from the prior art. Typically, such electrical components can comprise, for example, electrical coils or the like, wherein a conductor body is encapsulated with an injection-molded material during a plastic injection-molding process. One difficulty here can be ensuring that the electrically active element or the conductor body has a defined shape in the final production state. In particular, ensuring that the conductor body is encapsulated in a defined orientation and / or position usually requires considerable technical effort.

[0003] DE 10 2013 218 869 A1 describes a magnetic coil with a coil core made of plastic, a coil wire wound on the coil core and a protective layer made of plastic surrounding at least the area of ​​the coil wire.

[0004] US 3268645 A describes a method for embedding a winding in a thermoplastic mass. The winding is first arranged in a cavity defined by the walls of a mold, leaving a passage between the winding and the walls. The thermoplastic is then injected into the cavity.

[0005] US 2017 / 342954 A1 describes an ignition coil with a high-voltage terminal connected to a secondary coil and a lead terminal. The high-voltage terminal is housed in the housing together with a primary coil and the secondary coil, sealed with a filler resin.

[0006] DE 3 741 033 A1 describes a high-voltage transformer, wherein a coil housing and a primary coil arranged around the iron core in the coil housing are provided.

[0007] WO 2018 / 007514 A1 describes a transformer having a core limb with a longitudinal axis and a winding arrangement comprising a conductor. A group of stranded wires is divided into a first subgroup of stranded wires and a second subgroup of stranded wires, wherein the winding arrangement is integrated into a cast part.

[0008] The invention is based on the object of providing a method that improves the manufacturability of components provided with electrical conductor bodies, particularly with regard to a simple, rapid, and cost-effective measure. The object can also be based on the use of materials that are as technically simple to manufacture, cost-effective, and readily available as possible for the component provided with a conductor body, in particular for the conductor body.

[0009] The object is achieved by a method for producing a component provided with at least one electrically conductive conductor body according to claim 1. The dependent claims relate to possible embodiments of the method. Furthermore, the object is achieved by a component, in particular by a component comprising an electrical coil, according to claim 15.

[0010] The invention relates to a method for producing a component provided with at least one electrically conductive conductor body, wherein the conductor body is at least partially, in particular predominantly, surrounded by a material-locking and / or form-fitting injection-molded body formed from an injection-molded material, wherein the following method steps are carried out: (a) receiving the conductor body at least partially in or on a receiving region of a carrier body that delimits a receiving space, and (b) overmolding the carrier body provided with the conductor body at least partially with the injection-molded material to form a component comprising at least the conductor body, the carrier body, and the injection-molded body. The conductor body is received at least partially, preferably predominantly, particularly preferably almost completely, in or on a receiving region of a carrier body that delimits a receiving space.A nearly complete receptacle can be understood as meaning, for example, a complete receptacle or a receptacle such that a maximum of 25%, preferably a maximum of 10%, particularly preferably a maximum of 5%, of the volume of the conductor body is arranged outside a receptacle space.

[0011] An electrically conductive conductor body can, for example, be a conductor body made at least partially of metal, in particular of copper, which enables an electrical current to be conducted through it. The component comprising the at least one electrical conductor can, for example, form a component that comprises an electrical coil and is configured to generate or detect a magnetic field. The conductor body can, for example, be a magnetic field generating means and / or a magnetic field receiving means, in particular a corresponding electrical conductor. Alternatively or additionally, the component comprising at least one conductor body can form an electrical component or form part of a device, such as a transformer, a relay, an electric motor, or a loudspeaker.

[0012] The carrier body provided with the conductor body is overmolded at least partially, preferably predominantly, particularly preferably almost completely, with the injection-molded material to form a component comprising at least the conductor body, the carrier body, and the injection-molded body. In other words, a carrier body provided with a conductor body can be inserted into an injection mold and subsequently overmolded with an injection-molded material, e.g., a plastic injection-molded material. This results in a component or at least one component of the component in which the carrier body and the conductor body are integrally connected to one another via the injection-molded material due to the at least partially overmolded material or due to the curing injection-molded material.

[0013] For example, it can be provided that the injection-molded material surrounds the conductor body at least in sections, preferably predominantly, particularly preferably almost completely (with the exception of, for example, connection or contact areas). For example, the conductor body is directly or indirectly surrounded by the overmolded injection-molded body or the injection-molded material to at least 90%, preferably at least 95%, particularly preferably at least 98%. Alternatively or additionally, the assembly formed from the carrier body and the conductor body received in the receiving space of the carrier body can be surrounded by the overmolded injection-molded body to at least 90%, preferably at least 95%, particularly preferably at least 98%. Overmolding can, for example, also comprise overmolding, i.e. non-clamping overmolding.

[0014] The carrier body can, for example, have wall sections which form the receiving area delimiting the receiving space. The wall sections can, for example, influence or shape an insulation distance between adjacent conductor body sections and those received in respective receiving areas through their wall thickness and / or through the material and / or through the geometric shape (e.g. lattice structure) of the wall sections. In other words, the electrical breakdown or the electrical insulation effect between adjacent conductor body sections or between conductor body sections received in adjacent receiving spaces of the carrier body can be influenced or determined, for example, through the selection of the wall thickness of the wall sections of the carrier body. The carrier body can, for example,as a spacer for the conductor body sections accommodated in its receiving space, wherein the carrier body can perform its spacing function for the conductor bodies through its wall sections and in particular additionally through its keeping free receiving spaces for receiving spray material. This means, for example, that by maintaining receiving spaces in the deformed state of the carrier body, adding or filling with spray material can be facilitated or even made possible, so that in the overmolded state, the effective distance between the conductor body sections is formed by elements forming the carrier body itself and by the spray material introduced into the receiving spaces.

[0015] The wall section defining the receiving space can, for example, be formed at least partially, in particular entirely, as a grid body, initially ensuring a spacing of the conductor body sections. During overmolding, injection molding material can penetrate into the spaces in the grid body created by the spacing, thus forming the wall sections as solid bodies in the final production state, which are formed from the grid-shaped carrier body and the injection molding material.

[0016] Receiving the conductor body in the carrier body can comprise receiving the conductor body, at least in part, in particular completely, in or on a receiving area. The receiving area can have a shape that is at least in part, in particular completely, convex, concave, or flat. Thus, receiving can also be understood, for example, as "placing" or "inserting" the conductor body on or into a, in particular flat, section of the carrier body. It is possible for the receiving area to form a receiving space that includes a recess, wherein the conductor body can be received, at least in part, in particular completely, in an interior space of the recess.

[0017] According to the invention, after and / or during the reception of the conductor body in or on the carrier body, a change in the geometric shape of the carrier body takes place at least in sections, wherein with the change in the geometric shape of the carrier body, the conductor body at least in sections experiences or is subjected to a change in shape, in particular one that is similar or identical to the deformation of the carrier body. As a result of the change in shape, the carrier body and also the conductor body are transferred from a pre-configuration or pre-geometry into a target configuration or a target geometry. In this case, it can be provided that means which bring about the change in the geometric shape act at least partially through contact with the carrier body and that the geometric change in shape of the stranded wire body takes place through the contact of the carrier body with the stranded wire body attached to or inserted into or on the carrier body.In other words, the strand body is deformed indirectly via the forces acting on the carrier body and consequently via the deformation of the carrier body. For example, a means deforming the carrier body may have no contact with the strand body.

[0018] After the conductor body has been received in or on the carrier body, the geometric shape of the carrier body can, for example, preferably predominantly, particularly preferably almost completely, be changed, so that a predominant, in particular an almost complete, portion of the carrier body is subjected to a change in shape.

[0019] In other words, it can be provided that in the undeformed state the carrier body and the conductor body have a first geometric shape and after a deformation process the carrier body and the conductor body have a second geometric shape different from the first geometric shape.

[0020] A similar or identical deformation or change in shape of the conductor body compared to the carrier body means, for example, a deformation with a deformation or change in shape that differs by a maximum of 25%, preferably by a maximum of 15%, particularly preferably by a maximum of 5%. Alternatively or additionally, a similar deformation can include similarities in terms of rotational and / or translational deformation (e.g., by a maximum of 25%, preferably by a maximum of 15%, particularly preferably by a maximum of 5%, different stretching, compression, bending, etc.).

[0021] In a preferred exemplary embodiment, the change in shape of the conductor body and / or the support body after arranging the conductor body in or on the receiving area of ​​the support body can comprise a deformation such that the body volume formed by the conductor body and / or the support body becomes more compact. In other words, the deformation of the conductor body and / or the support body can reduce the packing size or the circumscribed space. So, for example, the conductor body and / or the support body has a higher density in the deformed state than in the undeformed state. The more compact nature of the conductor body and / or the support body can, for example, reduce the body volume of a reference body surrounding or circumscribing the conductor body and / or the support body (e.g., a cuboid, a cube, or a cylinder) by at least 10%, particularly preferably by at least 35%, particularly preferably by at least 50%, most preferably by at least 75%.

[0022] The deformation and, in particular, the increasing compactness of the conductor body and / or the carrier body can be advantageous in that the provision of the conductor body and / or the carrier body in the stretched or less compact state can be carried out more easily than in the deformed and thus more compact state. It can be provided that a carrier body has a rectilinear and / or strand-like shape, at least in sections, in the undeformed state and assumes a shape deviating from the rectilinear and / or strand-like shape before and / or after and / or during the assembly of the carrier body with the conductor body.

[0023] In particular, a targeted deformation of the conductor body can be simplified by receiving it in the carrier body and then jointly deforming the conductor body and carrier body, since the carrier body can be designed in such a way that it specifically deforms the conductor body received by it.

[0024] Through the targeted deformation of the conductor body and carrier body, the fill factor can be optimized or densified in terms of geometric space utilization. Alternatively or additionally, the deformation of the conductor and carrier body can also be used to specifically influence the fill factor in terms of the efficiency of the conductor body for a desired electrical effect of the conductor body. For example, by densifying the conductor body during the deformation of the conductor body, a higher effectiveness or a higher efficiency of the electrical and / or magnetic effectiveness of the conductor body can be achieved in a simple and cost-effective manner.

[0025] It is possible that at least one section of the conductor body and / or the carrier body experiences a linear and / or a rotational movement at least in sections during its deformation or during the geometric shape change, in particular the conductor body and / or the carrier body is bent and / or compressed during the deformation.

[0026] The linear and / or rotational movement performed during the deformation or geometric change in shape of the conductor body and / or the support body can comprise a compression of the conductor body and / or the support body. Compression, in this case, refers to a reduction in the length of the conductor body and / or the support body. Compression of an assembly comprising a support and conductor body can preferably be performed as a, in particular linear, "pushing-together" movement along an axis, in particular an axis of symmetry, of an electrical coil of a component comprising an electrical coil in the final state.

[0027] It is possible for the conductor body and / or the carrier body to have, at least in sections, at least one spiral shape, in particular a spiral shape comprising at least one basic conical shape and / or one basic cylindrical shape and / or one basic pyramid shape, in particular during and / or before their deformation. For example, in a carrier body that is at least in sections, in particular completely, linear or rectilinear, the conductor body can be inserted or mounted into the receiving space of the carrier body and, when the conductor body is inserted in or on the carrier body, this assembly can undergo a deformation or a geometric change in shape. This change in shape can, for example, be carried out in such a way that this assembly (carrier body and conductor body) is converted from a linear or rectilinear basic shape into a spiral shape.

[0028] A basic conical, cylindrical, or pyramidal spiral shape can be understood, for example, as a shape that at least essentially has the basic shape of a cone, a truncated cone, a cylinder (e.g., similar to a screw thread), a pyramid, or a truncated pyramid. The basic shape forms the overarching shape of the multiple turns or windings of the coil.

[0029] The conductor body and / or the carrier body can have a spiral shape, at least in sections, preferably predominantly, particularly preferably almost entirely. The course of the windings or of a linearly formed conductor body can, at least in sections, preferably predominantly, particularly preferably entirely, follow a strictly monotonic continuous function or represent a discontinuous, non-monotonic function. Consequently, the distance between individual windings and neighboring windings of the conductor body can be constant at least in sections or different at least in sections.

[0030] Preferably, the spiral shape is deformed, in particular compressed, during the deformation of the conductor body and / or the support body along an axis of the spiral shape, particularly preferably along an axis of symmetry of the spiral shape. In other words, a spiral shape, for example, the shape of the conductor body and / or the support body can be designed in the manner of a line wound on a lateral surface of a cone, a truncated cone, a pyramid, a truncated pyramid, or a cylinder (e.g., winding wire of the conductor body). The pitch of the line can be constant or variable, at least in sections, preferably predominantly, particularly preferably completely. In a preferred embodiment, the shape of the spiral can be in the form of a conical spiral.

[0031] A compression is understood to mean a pushing together or compression of the carrier body and / or conductor body.

[0032] It may prove advantageous if the carrier body has one or two or a plurality of spiral-like basic shapes. It may be advantageous for the spiral-like basic shapes to be designed such that each region forming a spiral-like basic shape forms a winding plane, particularly one extending perpendicular to a coil axis, in the deformed state or in the deformed compact state of the carrier body.

[0033] If the coil-like shape of the carrier and / or conductor body forms a pyramid-like shape, the base area of ​​such a pyramid can form any regular or irregular n-gon (e.g. square, pentagon, hexagon, heptagon, octagon,...).

[0034] A first section of the conductor body and / or support body can, for example, have a first, spiral-like, in particular conical or pyramid-like, basic shape, and a second section of the conductor body and / or support body can have a second, spiral-like, in particular conical or pyramid-like, basic shape, wherein a tapered region of the first spiral-like basic shape faces or faces away from a tapered region of the second spiral-like basic shape. The two tapered regions of the two basic shapes can face or face away from each other, thereby ensuring that there is no jump in the, in particular linear, conductor body, e.g., a conductor wire, in the transition region from the first to the second section, thus enabling a continuous course or a course with a small gradual degree of change in the geometric course of the conductor body.

[0035] Alternatively, it can be provided that the two widening regions of the conical or pyramidal basic shape of the first and second sections of the conductor body and / or the carrier body face each other. This leads to a comparable effect.

[0036] It is possible that after or during the receiving of the conductor body in or on a receiving area of ​​the carrier body, a first injection-molded body is injection-molded at least partially, in particular completely, onto the conductor body and / or the carrier body and that in a second injection-molded process carried out after the first injection-molded process, a second injection-molded body is injection-molded at least partially onto or onto the first injection-molded body and / or the conductor body and / or the carrier body. The first injection-molded process can, for example, be carried out before the change in the geometric shape or shape of the conductor and / or carrier body. In this case, the first injection-molded process can form a pre-injection molding, which together with a post-injection molding forms the finished component or an intermediate component stage. The pre-injection molding can, for example,serve to fix the conductor body in or on the carrier body. The pre-encapsulation can also comprise an element which can perform a function during the downstream post-encapsulation process. For example, this element can be used as a spacer and / or as a guiding and / or centering means when the assembly comprising the conductor body and the carrier body, provided with the pre-encapsulation, is received in the injection mold for carrying out the post-encapsulation. By means of such multiple encapsulation of the carrier and / or conductor body, the length of a creepage distance can be improved. In an optional further development, it is possible to carry out at least two injection molding processes, ie the component can be manufactured by carrying out two, three or more injection molding processes and correspondingly two, three or more injection molded bodies formed thereon.

[0037] In an optional embodiment, it can be provided that after receiving the conductor body and preferably after changing the geometric shape of the carrier body and thus also of the conductor body, at least some regions of the carrier body provided with the conductor body are overmolded, in particular at least some regions of pre-molded, with the carrier body. This pre-mold can comprise overmolding using a plastic, in particular implementing a plastic injection molding process. The pre-mold can, for example, be carried out in such a way that the carrier body is at least partially, in particular completely, fixed in its changed shape. Alternatively, the pre-mold can be carried out in the undeformed state or with the shape of the carrier and / or conductor body unchanged.

[0038] The carrier body provided with a pre-overmolding and the conductor body can, for example, be inserted into a molding tool in order to produce a further overmolding to form a further section that is attached to or molded onto the carrier body. The downstream overmolding can, for example, surround the pre-overmolding at least in sections. For example, the further overmolding (e.g., final overmolding) forms a housing for the carrier body. Preferably, the further overmolding (e.g., final overmolding) completely surrounds the carrier body and / or the conductor body from the outside, with the exception of exposed contacts. It is possible for the pre-overmolding to comprise defined holding means by means of which the pre-overmolding carrier body can be held and / or aligned in a molding tool used to apply or apply a further overmolding, for example to form the cavity provided for the further overmolding.

[0039] It is possible that after or during the receiving of the conductor body in or on a receiving area of ​​the carrier body, the carrier body provided with the conductor body is received at least partially, in particular completely, in or on a receiving volume of a base body, wherein during the overmolding, in particular by means of the injection molding material, the conductor body, the carrier body and the base body are connected to one another at least partially in a material-locking and / or form-fitting manner. A material-locking connection can be achieved by direct contact of the injection molding material with the conductor body, the carrier body and the base body, whereby the injection molding material can form a material-locking connection of the body and thus also connect these to one another. In other words, the conductor body, the carrier body and the base body are injection-molded with the injection molding material or the form-fitting manner in an injection-molding process, in particular in a plastics injection-molding process.with the plastic material, injected or over-molded to form an injection-molded body, so that a component comprising the conductor body, the carrier body, the injection-molded body and the base body is produced.

[0040] The base body can be designed, for example, as a housing or a housing part into which the carrier body provided with the conductor body is inserted, in particular in its deformed state, at least in sections, preferably predominantly, particularly preferably almost completely, and in the at least partially inserted state, the injection-molded material is injected onto or around it, so that an assembly that is connected to one another in a materially and / or form-fitting manner is formed.

[0041] The receiving volume of the base body can, for example, be formed as a cavity which is defined at least in sections, directly or indirectly, by base body walls formed by the base body. In other words, base body walls, in particular those formed integrally with the base body, define a receiving volume. Preferably, the base body walls are produced at least in sections, preferably completely, during a manufacturing process for the base body. For example, the base body is a plastic injection-molded component, wherein the base body walls are formed at least in sections, in particular completely, during the plastic injection-molded process to form the base body.

[0042] It is possible for at least one contact means, which forms an electrically conductive connection with the conductor body, to be arranged (a) in or on the carrier body and / or (b) in or on the receiving volume of the base body before or during the overmolding, to be arranged. The contact means can, for example, be designed as a plug-in contact in order to electrically connect a plug to the conductor body via the contact means in the final production state of the component. Preferably, at least one contact means region of the contact means is exposed after the overmolding and / or a region of at least one contact means protrudes from the main extension volume of the component, in particular from the injection-molded body, after the overmolding. Preferably, the contact means is surrounded circumferentially or transversely to a longitudinal extension and in a ring-like manner by the injection-molded material or the injection-molded body.It is also possible for the contact means to form a force-fit, form-fit, and / or material-fit connection with the carrier body prior to overmolding and / or before deformation of the carrier body. For example, the contact means can be pre-fixed to the carrier body prior to overmolding, thus providing a certain positional and / or alignment fixation for overmolding. The (final) fixation of the contact means for the intended use of the component can preferably be achieved during overmolding and thus by the injection-molded body.

[0043] In a preferred embodiment, it can be provided that (a) in or on the carrier body and / or (b) in or on the receiving volume of the base body, at least one iron core and / or electrical component and / or magnetic field-guiding element is arranged before or during the encapsulation and is at least partially encapsulated with the injection-molded material during the encapsulation. The iron core can, for example, be formed at least partially from ferrite. The electrical component can, for example, be a battery and / or a circuit board and / or an integrated electrical circuit and / or an element operating on the principle of RFID (radio-frequency identification). A magnetic field-guiding element can, for example, have a magnetic field directing and / or guiding and / or strengthening property.

[0044] The iron core and / or the electrical component and / or the magnetic field-guiding element can be arranged in or on the carrier body and / or in or on the receiving volume of the base body prior to overmolding, in particular prior to deformation of the carrier body, preferably connected in or on the carrier body and / or to the receiving volume of the base body in a materially bonded and / or positively bonded and / or force-locked manner (e.g., in the sense of pre-fixing). Alternatively or additionally, the iron core and / or the electrical component and / or the magnetic field-guiding element can be arranged in or on the carrier body prior to deformation of the carrier body, in particular fixed in or on the carrier in the sense of pre-fixing.

[0045] It is possible to use a conductor body designed as a stranded wire body and composed of at least one group of electrically conductive individual wires. Preferably, the stranded wire body comprises, at least in sections, in particular entirely, at least one group of electrically conductive individual wires, which are designed as high-frequency stranded wires and / or high-voltage stranded wires and / or as individual wires insulated from one another by an insulating layer, in particular an insulating layer comprising a lacquer layer and / or silk. Typically, in high-frequency stranded wires, the individual wires are insulated from one another by a lacquer layer, even though they carry the same potential. This can reduce or prevent the influence of a skin effect at high frequencies, since otherwise only a small part of the total cross-section would effectively "participate" in the current transport.The individual wires of the stranded wire body can, for example, consist at least predominantly of copper. The individual wires of the stranded wire body can, for example, comprise a plurality of individual wires and can optionally be enclosed by a common insulating material, e.g., an insulating sheath. Such groups of individual wires enclosed by a common insulating material can be referred to as stranded wires, and several such stranded wires combined in a common cable can be referred to as cores.

[0046] The insulating layer and / or the insulating means can, for example, comprise a wrapping and / or a coating of at least a portion, in particular all, of the individual wires of the stranded wire body. For example, the insulating layer and / or the insulating means can be made of plastic or a fiber material, preferably a plant or animal fiber material, particularly preferably silk.

[0047] Since in the case of a conductor body having an insulating layer and / or an insulating means, in particular one as a stranded wire body with an insulating layer between the individual wires, the insulating layer and / or the insulating means also experiences mechanical stress (e.g. due to bending) during the deformation of the carrier body and the conductor body, the carrier body can relieve the mechanical stress on the insulating layer and / or the insulating means, since the carrier body can perform a guiding function for and / or a more gentle deformation, e.g. low compressive and / or tensile forces per surface section acting on the insulating layer and / or the insulating means.In other words, the carrier body can specifically influence the forces acting on the insulating layer and / or the insulating material during deformation, thus reducing the demands on the insulating layer.

[0048] Furthermore, by means of the carrier body walls creating a spacing between sections of the conductor body, basic insulation can be achieved between the conductor body sections, such that the degree of insulating effect of an insulating means and / or an insulating layer of the conductor body can be reduced. This can make it possible, for example, to avoid the use of high-quality technical silk as an insulating material or insulating material component for the insulating means and / or for the insulating layer, such that a more cost-effective component can be achieved. It can also prove advantageous if the carrier body and / or the injection-molded body enable a spacing function between conductor body sections, such that conductor bodies can be used which have no or a weaker insulating layer and / or insulating means, since these insulating layer orThe insulating function can be performed at least in part by the carrier body and / or the injection-molded body.

[0049] It is possible that the carrier body and / or the base body is or was produced at least in sections, in particular completely, from an injection molding process, in particular a plastic injection molding process, and / or from an additive manufacturing process, also referred to as 3D printing.

[0050] For example, it can be provided that a counterholder is used which, during the deformation and / or during the overmolding, at least partially, preferably predominantly, rests against a surface area of ​​the carrier body which faces radially inwards towards the center of the deformed state or in the target geometric state. Through the contact of the counterholder with the surface area of ​​the carrier body, its targeted deformation during the deformation can be achieved and / or supported. In other words, a reproducible and / or targeted deformation of the carrier body and, if applicable, of the conductor body accommodated in or on the carrier body can be enabled by the use of the counterholder, wherein the counterholder counteracts a deformation force acting on the carrier body as a stop or as a counterbearing, at least partially, and thus enables a targeted deformation of the carrier body. For example,A counterholder can be used to bend a carrier body, which in its undeformed initial state is at least partially, in particular completely, rectilinear and / or stretched, around the counterholder, in particular by wrapping it more than once around the counterholder. The overmolding of the carrier body can take place before, during, or after the removal or withdrawal of the counterholder from the carrier body. By applying the counterholder to the carrier body, which is at least partially, in particular completely rectilinear, with this action, it can be deformed into a coil body, for example.

[0051] It is possible for the carrier body and / or the base body to be made, at least in sections and in particular entirely, from a plastic, preferably from a thermoplastic. For example, the following plastics can be used: polyamide (PA) and / or polyphenylene sulfide (PPS) and / or polybutylene terephthalate (PBT) and / or polybutylene terephthalate (PBT) with a glass fiber content of a maximum of 15 vol.%, in particular a maximum of 5 vol.%. It is advantageous, in particular, if the plastic used for the carrier body has a formability and / or hardness and / or elasticity and / or fracture strength that enables the predefined change in geometric shape to be carried out without material failure or cracking.

[0052] In principle, an injection molding material can be a thermoplastic or a thermosetting plastic. The term "plastic" can in all cases also include mixtures of different plastics and / or mixtures of plastics with other materials, such as additives, fillers, etc. Examples of thermoplastics were given above. Examples of thermosetting plastics are epoxy resins, polyurethane resins, polyester resins, and phenolic resins. Thermosetting plastics can therefore be based on epoxies, polyesters, polyurethanes, or phenols.

[0053] It is possible for the carrier body to comprise at least two carrier partial bodies, wherein the carrier partial bodies are assembled before and / or during the reception of the conductor body in or on the reception area of ​​the carrier body. The carrier body can thus be designed as a built body, wherein at least two carrier partial bodies are connected to one another in a force-fitting and / or material-fitting and / or form-fitting manner. The force-fitting and / or material-fitting and / or form-fitting connection of the carrier partial bodies to form the carrier partial body can take place before and / or during the overmolding of the carrier body. In an exemplary embodiment, the reception area or the reception space for receiving the conductor body is only formed by assembling or joining the carrier partial bodies, so that the conductor body is only received after the carrier partial bodies have been assembled.In other words, it may prove advantageous if a carrier body is used which comprises at least two carrier partial bodies, wherein at least two carrier partial bodies each comprise a receiving partial area for at least partially forming the receiving area or the receiving space, wherein in particular at least in the state of the overmolded component and thus after the overmolding of the carrier body and conductor body, the at least one conductor body is received or arranged in the at least two receiving partial areas.

[0054] Furthermore, a carrier body can optionally be used, the receiving area of ​​which has, at least in sections, an L-shaped and / or a U-shaped and / or a V-shaped and / or a C-shaped and / or a W-shaped cross-sectional geometry. At least one conductor body can be received or arranged in the interior spaces of the L-, U-, V-, C-, or W-shapes. The aforementioned shapes, in particular the C-shape, can be claw-shaped at least in sections, in particular completely, and can at least in sections, in particular completely, encompass the conductor body received in its receiving space. The carrier body can have, at least in sections, preferably predominantly, particularly preferably completely, a constant cross-sectional geometry. The L-shaped and / or U-shaped and / or V-shaped and / or C-shaped and / or W-shaped cross-sectional geometry of the receiving area of ​​the carrier body can, for example, be defined or shaped by wall sections of the carrier body.be formed.

[0055] It is possible to use a carrier body whose receiving area or receiving space has a first axial length in a first receiving area section and a second axial length, different from the first axial length, in a further receiving area section. Preferably, a first receiving area section located closer to the center of the component has a greater axial length than a further receiving area section located further away from the center of the component. An axial length of the receiving area section means the length of a receiving area section parallel to or along a longitudinal and / or symmetry axis of the component. In particular, the axial length of the receiving area section runs parallel to or along the symmetry axis of a coil-like section of the conductor body of the component.Preferably, the center of the component can form its axis of symmetry, in particular the axis of symmetry of a coil-like conductor body of the component.

[0056] Because the axial length of the receiving area section is greater at a more central location of the component than at a location further away from the center, it can be achieved, for example, that with a constant cross-sectional area of ​​the conductor body, a first receiving area has a first cross-sectional shape (e.g. rectangular or oval with a different length to width) and a second cross-sectional shape (e.g. square or round) that differs from the first cross-sectional shape in a further receiving area.

[0057] In a further optional embodiment, a carrier body can be used which, at least in sections, comprises a guide device on a surface of at least one wall section facing away from the receiving area of ​​this carrier body, wherein the guide device carries out targeted guidance of injection material brought towards or injected into the carrier body during overmolding. Preferably, at least one guide device on the carrier body side is adapted to the geometric shape of a base body and / or the position and / or orientation of at least one injection opening of an injection mold for overmolding the carrier and conductor body received therein, in order to achieve defined or targeted overmolding of the carrier and conductor body. Preferably, the guide device also achieves, at least in sections, targeted overmolding of the base body or of the carrier and conductor body attached in or on a base body.It can also optionally be provided that the guide device guides spray material to free spaces between carrier body sections and / or conductor body sections as predominantly as possible, in particular as completely as possible, in order to fill or overmold these spray material. Alternatively or additionally, the guide device can have a spacing function, so that in the deformed state of the carrier body, the guide device keeps carrier body sections at a defined distance from one another in order to provide or create any free spaces for the passage and / or filling of spray material.

[0058] It is possible for at least one conductor body received in the receiving area of ​​the carrier body to be held or connected in a form-fitting and / or material-fitting and / or force-fitting manner in the receiving area by means of a holding means, in particular on the carrier body side, at least in the state before the carrier body provided with the conductor body is overmolded with the injection-molded material. The holding means on the carrier body side can, for example, be formed integrally with the carrier body, i.e. made of the same material. For example, the holding means can be formed as a clamping element, in particular on the carrier body side, and can act in a clamping manner on a conductor body placed in or on a receiving area or in or on a receiving space of the carrier body.In other words, a conductor body placed in or on the conductor body can be pre-fixed by means of at least one holding means, wherein a final fixation takes place during the overmolding and thus by means of the injection material.

[0059] It is possible that, during the receiving of the conductor body in or on the receiving area of ​​the carrier body, the conductor body is guided at least partially, in particular completely, into or onto the receiving area by means of a guide means, in particular on the carrier body side. For example, the guide means can be designed as a sliding or guide bevel, which supports the introduction of or the reaching of a desired position of the conductor body within the receiving space or the receiving area of ​​the carrier body. The guide means can also serve, for example, as an end stop to support the reaching of a desired position of the conductor body.It is possible for an element of the carrier body to fulfil the function of the guide means and the function of the holding means, thus enabling both a guidance of the conductor body at least in sections on its way into the receiving space of the carrier body and the holding of the carrier body in the receiving space.

[0060] During the change in the geometric shape of the conductor body and / or the carrier body, for example, (a) at least partial, in particular complete, guidance of a relative movement of at least two carrier body partial regions can take place by means of a guide section, in particular on the carrier body side, and / or (b) a positive and / or non-positive and / or material-locking connection of at least two connecting sections, in particular on the carrier body side. The guidance of the relative movement of the at least two carrier body partial regions by means of the guide section can be effective at least partially, preferably predominantly, particularly preferably completely, over the path to be covered by the relative movement of the at least two carrier body partial regions. The guide section can, for example,as a section of the carrier body which acts as a guide and which interacts at least in sections with a counter-guide section during a deformation process of the carrier body in such a way that an at least partially defined relative movement of two partial body regions of the carrier body is achieved.

[0061] A positive and / or non-positive and / or materially bonded connection, at least in sections, of at least two connecting sections on the carrier body side can be achieved, for example, by connecting elements arranged or formed on the carrier body side. For example, at least one engagement element, e.g. on a first carrier part, and a counter-element, e.g. on a further carrier part, are provided on the carrier body, which are designed such that a non-positive and / or positive connection can be achieved. Specifically, the non-positive and / or positive connection can be designed as a snap-locking connection or as a clamping connection. For this purpose, a locking hook can be provided on a first fastening section of the carrier body and a fastening section as a locking hook receptacle can be provided on a further region of the carrier body.The connecting section can preferably be designed such that it holds or fixes the carrier body in the deformed state, in particular in a more compact state compared to the initial state. In other words, the connecting section can prevent the deformed, in particular compressed, carrier body from springing back. As a result, the deformed carrier body, possibly under prestress, reliably remains in its desired state, in particular in a more compact state, and can be subjected to an encapsulation or overmolding process in this state. For example, the carrier body and conductor body in the compact state, preferably together with a base body, are inserted into an injection mold and overmolded with injection material.

[0062] It is possible for at least one connecting section to be formed on a contact means. Thus, it is possible for the contact means to be attached to the carrier body prior to deformation of the carrier body, and for the connecting section function to be achieved or to be able to be achieved, at least in sections, by (a) the contact of two such contact means or (b) the contact of a contact means with a mating region of a carrier body section. The two connecting partners can cooperate in such a way that a positive and / or non-positive connection or holding of the carrier body is enabled. Consequently, springing back of the deformed carrier body can be prevented, wherein the connecting section function can be formed or provided not on the carrier body itself, but at least partially on the contact means.

[0063] In a further advantageous embodiment, it can be provided that a carrier body is used which has at least two mutually corresponding guide sections and / or at least two mutually corresponding connecting sections arranged or formed on different wall sections on the carrier body. For example, the corresponding guide sections and / or connecting sections are arranged or formed such that they (a) have an identical or similar (e.g., a maximum of 10%, preferably a maximum of 5% difference) radial distance from a center of the carrier body and / or the component (b) lie on a common plane running perpendicular to the axis of the component 1. Mutually corresponding guide and / or connecting sections means that these corresponding sections interact with one another in such a way that a guiding or connecting function is carried out orcan be.

[0064] It is also possible for a first conductor body to be accommodated in a receiving area delimiting a first receiving space and for a further conductor body to be accommodated in a receiving area delimiting a further receiving space, in particular prior to overmolding at least one carrier body provided with the conductor body with an injection-molded material. Preferably, both conductor bodies, or the conductor bodies located in the different receiving spaces, are at least partially enclosed or overmolded with injection-molded material in a common repointing process step. The at least two receiving spaces can be separated from one another in such a way that the conductor bodies arranged in the respective receiving spaces cannot touch one another.

[0065] It is possible for the component to comprise at least two conductor bodies which run in a screw-like or coil-like manner and are separated from one another, in particular electrically, by a wall section of the carrier body and / or by injection-molded material in the state of the finished or intended component. It is possible for receiving spaces which are at least partially, in particular completely, separate from one another to be provided on the carrier body side for receiving different conductor bodies. In this case, a multi-part carrier body can be provided to form the different receiving spaces. The at least two conductor bodies can, for example, be made from different materials and / or from a different number of individual wires or have a different cross-section.

[0066] In addition to the method for producing a component provided with at least one electrically conductive conductor body, the invention also relates to a component, in particular an electrical coil, comprising a conductor body and a carrier body, produced using a method described herein. The component can be installed in a vehicle, in particular in a motor vehicle.

[0067] The invention also relates to a device for producing a component comprising a conductor body and a carrier body according to a method described herein. This device can, for example, comprise a counterholder, which acts as a deformation-imparting element during the deformation of the carrier body provided with the conductor body.

[0068] All advantages, details, embodiments and / or features of the method according to the invention are transferable or applicable to the component according to the invention and to the device according to the invention for producing a component comprising a conductor body and a carrier body.

[0069] The invention is explained in more detail using exemplary embodiments in the drawings. In the drawings: Fig. 1 is a schematic exploded view of a component according to an embodiment; Fig. 2 is a schematic view of a component in the final state according to an embodiment; Fig. 3 is a perspective semi-transparent schematic view of a component in the final state according to an embodiment; Fig. 4 is a perspective view of a carrier body in an undeformed state according to an embodiment; Fig. 5 is a perspective view of a carrier body in a deformed state according to an embodiment; Fig. 6 is a schematic sectional view of the carrier body in a deformed state according to an embodiment; Fig. 7 is a schematic view of a carrier body in an undeformed state according to an embodiment; Fig. 8 is a schematic view of a carrier body in an undeformed state according to an embodiment; Fig. 9 is a schematic view of a carrier body according to Figure 6 or7 in a deformed state; Fig. 10 shows a schematic detailed representation of a close region of two adjacent carrier body sections according to an exemplary embodiment; Fig. 11 shows a schematic detailed representation of a close region of two adjacent partial body sections according to an exemplary embodiment; Fig. 12 shows a perspective schematic representation of a carrier body in a deformed state according to an exemplary embodiment; Fig. 13 shows a perspective schematic representation of a conductor body designed as a stranded wire body.

[0070] A method for producing a component 1 provided with at least one electrically conductive conductor body 2 is explained below. The conductor body 2 of the final product, ie of the component 1 in the finished state, is surrounded at least in sections, in particular predominantly, in a material-locking and / or form-locking manner by an injection-molded body 4 formed from an injection-molded material 3. As shown in Figure 2It can be seen that a spray material is arranged or formed or sprayed on between and / or around a group of components, namely between and / or around a conductor body 2, a carrier body 7 and a base body 16.

[0071] The method provides as method steps that the conductor body 2 is received at least in sections in or on a receiving area 6 of a carrier body 7 delimiting a receiving space 5, cf. Figure 1 , there, a carrier body 7 is shown, which has a U-shaped receiving space 5 defined by wall sections 27 on the carrier body side. The conductor body 2 is introduced into this U-shaped receiving space 5. In a subsequent method step, the carrier body 7 provided with the conductor body 2 is overmolded, at least in sections, with the injection-molded material 3 to form a component 1 comprising at least the conductor body 2, the carrier body 7, and the injection-molded body 4. Figure 1 shows an exploded view of the conductor body 2, the carrier body 7, the base body 16 and a contact means 17. The conductor body 2, the carrier body 7 and the contact means 17 can be attached or inserted into a receiving volume 15 of the base body 16 and finally, at least in sections, be overmolded by an injection-molded material 3, so that the component 1 is in its final production state, cf. Figures 2 and 3 .

[0072] After and / or during the accommodation of the conductor body 2 in or on the carrier body 7, a change in the geometric shape of the carrier body 7 takes place at least in sections, wherein with the change in the geometric shape of the carrier body 7, the conductor body 2 undergoes at least in sections a change in shape, in particular in comparison with the deformation of the carrier body 7, similar or identical. An exemplary change in shape of the carrier body 7 can be seen from the comparison of the Figures 4(undeformed state) and Figure 5 (deformed state) is apparent. If, prior to the deformation of the carrier body 7, the conductor body 2 is inserted or placed into the receiving area 6 of the carrier body 7, a change in the shape of the conductor body 2 also occurs simultaneously or slightly offset in time to the change in shape of the carrier body 7. It is possible that the change in shape of the conductor body 2 and / or the carrier body 7 after the arrangement of the conductor body 2 in or on the receiving area 6 of the carrier body 7 comprises a deformation such that a body volume 8 formed by the conductor body 2 and / or the carrier body 7 becomes more compact. The body volume 8 of the conductor body 2 and the carrier body 7 can be understood as a reference volume or standard volume (e.g., by circumscribing these bodies 2, 7 by a cuboid, cylinder, or cube) of these two bodies 2 and 7 in order to indicate the compactness of the bodies 2, 7. In the Figures 4The two basic shapes 11, 12 approximately indicate the body volume 8; in Figure 5 The body volume 8 is marked with a dashed line. In other words, in the undeformed state, the carrier body 7 and / or the conductor body 2 is present in a state comprising a larger filling dimension than in the deformed state. The deformed state can, for example, correspond to the final production state of at least the carrier body 7 and / or the conductor body 2, so that in the deformed state of the two bodies 2, 7, overmolding and thus their integral connection enables the fixation of this target state or this target geometry.

[0073] At least one section of the conductor body 2 and / or the support body 7 can perform or undergo a linear and / or rotational movement during its deformation. In particular, the conductor body 2 and / or the support body 7 is bent at least partially, in particular completely, during the deformation.

[0074] In a method step preceding the deformation of the carrier body 7, it can be provided that during the introduction or reception of the conductor body 2 into or on the receiving area 6 of the carrier body 2, the conductor body 2 undergoes a targeted change in shape. For example, a conductor body 2 can undergo an elastic and / or plastic change in shape or deformation during its introduction into the receiving area 6 due to the counterforce acting on the conductor body 2 by means of the carrier body 7. In this case, the conductor body 2 can preferably follow the shape predetermined by the, in particular stiffer, carrier body 7 or its receiving area surface. In other words, by receiving the conductor body 2 in or on the carrier body 7, the carrier body 7 can have a shaping effect on the conductor body 2.For example, it is possible to achieve even more complex or technically difficult changes in the shape of the conductor body 2 in a simple and cost-effective manner by a targeted design of the carrier body 7 and its shaping effect during the reception of the conductor body 2.

[0075] The conductor body 2 and / or the carrier body 7 can, in particular prior to its deformation, at least in sections, preferably predominantly, particularly preferably completely, have at least one spiral-like shape 9, in particular a spiral-like shape 9 comprising at least one conical basic shape and / or one cylindrical basic shape and / or one pyramidal basic shape. It is possible that the spiral-like shape 9 is compressed along an axis 10 of the spiral-like shape 9, particularly preferably along an axis of symmetry of the spiral-like shape 9, or is subjected to compressive forces directed towards the center of the spiral-like shape 9 during the deformation of the conductor body 2 and / or the carrier body 7. As shown, for example, in the Figure 4 As shown, the carrier body 7 (and / or the conductor body 2) may have a curved line-like shape, wherein this line-like shape extends in the manner of at least one spiral within the space.

[0076] In other words, the carrier body 7 provided with the conductor body 2 can be compressed in such a way that components of the carrier body 7 are immersed within gaps predetermined by the shape of the carrier body 7, cf. Figures 4 and 5 .

[0077] It is possible for a first section of the conductor body 2 and / or carrier body 7 to have a first, spiral-like, in particular conical or pyramid-like, basic shape 11 and for a second section of the conductor body 2 and / or carrier body 7 to have a second, spiral-like, in particular conical or pyramid-like, basic shape 12, wherein a tapered region 13 of the first spiral-like basic shape 11 faces or faces away from a tapered region 14 of the second spiral-like basic shape 12. A spiral-like basic shape 11, 12 can be understood, for example, as a course of at least one section, in particular a complete course, of a carrier body 7 and / or a conductor body 2, according to which a section of the carrier body 7 and / or the conductor body 2 runs at least substantially in or on a basic shape surface of a basic shape 11, 12. Thus, as in Figure 4shown, the linear course of the carrier body 7 extends essentially along a surface of a pyramid. In Figure 4 In the example shown, the linear support body 7 runs along the ends of two pyramid-shaped or pyramid-like basic shapes 11, 12, which are facing their tips or tapered areas. The basic shapes 11, 12 were Figure 4 schematically visualized by dashed two-dot lines.

[0078] In the Figures 7 and 8 Further or alternative configurations of the carrier body 7 are shown in abstract form, in which case the carrier body 7 and / or the carrier body 7 provided with a conductor body 2 can have pairwise, sectionally tapered spiral-like shapes. In Figure 7Four, e.g., conical, basic shapes 11, 12 are shown, with the upper and lower pairs 42, 42' of the basic shapes 11, 12 each facing each other with their extended end regions. In the deformed or compressed state (see Figure 9 ) the carrier body sections are nested or moved into each other at least in sections. Figure 8 the basic shape pairs 42, 42' each point towards each other with their tapered end regions, whereby also for this embodiment their deformed state consists of Figure 9 is evident. The Figure 8 The arrows 43 shown indicate the winding direction of the conductor body 2 within the basic shape 11, 12, wherein it can be seen that the winding direction or the direction of rotation of a carrier body-side receiving space course remains constant inside and outside the basic shape pairs 42, 42'.

[0079] After and / or during the reception of the conductor body 2 in or on a reception area 6 of the carrier body 7 provided with the conductor body 2, the group formed from the conductor body 2 and the carrier body 7 can be received at least partially, in particular completely, in or on a reception volume 15 of a base body 16, wherein during the overmolding, in particular by means of the injection-molded material 3, the conductor body 2 and the carrier body 7 and the base body 16 are connected to one another at least partially in a materially bonded and / or positively bonded manner. The base body 16 can, for example, have a pot-like shape or a cup shape, so that an inner reception volume 15 is surrounded or defined by a circumferential wall extending circumferentially on the base body side, in particular in the manner of a closed ring. It is possible for the base body 16, which in particular has a pot-like shape, to have a recess 37.A collar section 34 can extend from this recess 37, for example. The collar section 34 can, for example, have a cylindrical shape and, in the manner of a cylindrical wall, form a channel 35 extending from the recess 37 over the main extension volume 36 of the base body 16. In other words, the channel 35 traverses the base body 16, wherein the collar section 34, in particular on the base body side, delimits the channel 35 from the receiving volume 15 of the base body 16, in particular in a spray material-tight manner during the injection state. It can be provided that the collar section 34 at least partially, in particular completely, prevents spray material 3 from reaching or penetrating the channel 35 during the injection of spray material 3 into or onto the receiving volume 15 of the base body 16.

[0080] It may prove advantageous if the channel 35 extends substantially coaxially to an axis 10 of a conductor body 2 and / or carrier body 7, in particular a spiral-shaped one, received in the receiving volume 15 of the base body 16.

[0081] In an advantageous embodiment, it can be provided that (a) in or on the carrier body 7 and / or (b) in or on the receiving volume 15 of the base body 16, at least one contact means 17 is arranged before or during the overmolding, which forms an electrically conductive connection with the conductor body 2. In this case, for example, at least one contact means region 18 of the contact means 17 can be exposed after the overmolding and / or at least one contact means region 18 of the at least one contact means 17 protrudes from the main extension volume of the component 1 after the overmolding, cf. Figure 2. The contact area 18 protruding from the main extension volume 36 of the base body 15 can serve, for example, as an interface or as a plug contact for a corresponding plug / socket counterpart (not shown).

[0082] It can optionally be provided that (a) in or on the carrier body 7 and / or (b) in or on the receiving volume 15 of the base body 16, at least one iron core (not shown) and / or electrical component (not shown) and / or magnetic field-guiding element (not shown) is arranged before or during the overmolding and is overmolding at least in sections with or by the injection-molded material 3 during the overmolding. This makes it possible to connect further elements of the component 1 to the carrier body 7 and / or the base body 16, in particular in a non-detachable manner, during the overmolding.

[0083] A conductor body 2 can, for example, be designed as a stranded wire body 19 and have at least one group of electrically conductive individual wires 38, cf. Figure 13. The stranded wire body 19 preferably has, at least in sections, in particular completely, at least one group of electrically conductive individual wires 38, which are designed as high-frequency stranded wires and / or high-voltage stranded wires and / or as individual wires 38 insulated from one another or from one another by an insulating layer 39, in particular by an insulating layer 39 designed as a varnish layer. The group of individual wires 38, each provided with an insulating layer 39, for example, can optionally be insulated from the environment 41 by at least one insulating means 40. The environment 41 thus means the area directly adjacent to the insulating means 40; this can be, for example, an injection-molded body 4 or a carrier body 7. An insulating means 40 can also be used in a conductor body 2 comprising a solid wire.

[0084] In an advantageous embodiment, the use of the carrier body 7 can achieve that an insulating means 40 of the conductor body 2, in particular of the stranded wire body 19, and / or an insulating layer 39 of a stranded wire body 19 has to fulfill a lower requirement with regard to their electrical effectiveness or their electrical insulating effect, since the actual electrical insulating function can be carried out at least in part by the carrier body 7 and / or by the injection-molded body 4. In a further embodiment, an insulating means 40 of the conductor body 2 can be dispensed with at least in sections, in particular completely. In this case, for example, the insulating means 40 can be dispensed with at least in sections, in particular completely, along the longitudinal axis or along the course of the conductor body 2 and / or the individual wires 38.

[0085] The carrier body 7 and / or the base body 16 can be manufactured at least in sections, in particular entirely, using an injection molding process and / or an additive manufacturing process. For this purpose, for example, the carrier body 7 and / or the base body 16 can be formed at least in sections, in particular entirely, from a plastic, preferably from a thermoplastic. Particularly preferably, the plastic is selected such that it can be processed using an injection molding process, so that, for example, the carrier body 7 and / or the base body 16 can be manufactured, for example, using a plastic injection molding process.

[0086] The carrier body 7 can, for example, comprise at least two carrier partial bodies, wherein the carrier partial bodies are assembled before and / or during the reception of the conductor body 2 in or on the reception area 6 of the carrier body 7 (not shown). In other words, the carrier partial bodies can initially be present as separate elements, in particular elements produced separately from one another, and can be connected to one another in a force-fitting and / or form-fitting and / or material-fitting manner before or during the reception of the conductor body. For example, the carrier partial bodies are assembled or connected by means of a clip connection (i.e. a snap-lock connection), wherein the sections forming the clip connection can be formed, in particular in one piece, on the carrier partial bodies. By means of a connection consisting of several separate parts orBy using a support body 7 having a support part body, the production of the support part body 7 can be simplified and / or the possibilities for the structural geometric design of the support element 7 can be expanded.

[0087] A carrier body 7 can, for example, comprise at least two carrier sub-bodies, wherein at least two carrier sub-bodies each comprise a receiving sub-region for at least partially forming the receiving region 6. Optionally, at least in the state of the overmolded component 1, the at least one conductor body 2 can be received in the at least two receiving sub-regions. Receiving sub-regions are to be understood as longitudinal sections along the course of the carrier body 7.

[0088] For example, a carrier body 7 can be used whose receiving area 6 has, at least in sections, an L-shaped and / or a U-shaped and / or a V-shaped and / or a C-shaped and / or a W-shaped cross-sectional geometry. In particular, the carrier body 7 has, at least in sections, preferably predominantly, particularly preferably completely, a constant cross-sectional geometry. Figure 6 The embodiment shown shows a predominantly constant cross-sectional geometry of the carrier body 7, according to which only the innermost turn or the innermost carrier section has a flatter shape than the other carrier sections arranged further outwards.

[0089] A receiving area 6 of the carrier body 7 can, for example, have a first axial length 24 in a first receiving area section 23 and a second axial length 24' that differs from the first axial length 24 in a further receiving area section 23'. A first receiving area section 23 located closer to the center 25 of the component 1 and / or the carrier body 7 preferably has a greater axial length 24 than a further receiving area section 23' located further away from the center 25 of the component 1 and / or the center 25 of the carrier body 7, which has an axial length 24', cf. Figure 6. An advantage can arise from the fact that, if the inner diameter of a component 1 designed as an electrical coil is predetermined, a flattening of the innermost and / or outermost carrier body section or receiving area section 23, 23' can represent a suitable and simple means for reducing the radial annular ring length 20 of the carrier body 7 in the deformed state.

[0090] For example, a carrier body 7 can be used which, at least in sections, in particular completely, comprises a guide device 28 on a surface 26 of at least one wall section 27 facing away from the receiving area 6, wherein the guide device 28 carries out a targeted guidance of injection material 3 brought to the carrier body 7 during the overmolding. In this case, the guide device 28 can, for example, have a projection with a defined geometric shape which cooperates with a corresponding recess in an opposite wall section 27, 27' in order to achieve a defined end position of the wall sections 27, 27', cf. Figure 11. Preferably, at least one carrier body-side guide device 28 is adapted to the geometric shape of a base body 16 and / or the position and / or orientation of at least one injection opening of an injection molding tool for overmolding the conductor and carrier body 2, 7 received therein, in order to achieve a defined overmolding of the conductor and carrier body 2.

[0091] The guide device 28, in particular on the carrier body side, can, for example, alternatively or additionally have a spacing function by means of which at least two wall sections 27, 27' of the carrier body 7 are held at a defined distance 21, at least in the deformed state of the carrier body 7. Alternatively or additionally, a separate element, e.g., a spacing device, of the carrier body 7, in particular of the wall section 27, 27', can be provided to achieve such a distance 21.

[0092] The gap formed by the distance 21 can be used for the passage and / or placement of injection material 3 during overmolding. Consequently, the guide device 28, 28' or the spacing device can ensure a gap during overmolding in order to be able to carry out the overmolding process in a more defined and / or faster manner, see. Figure 10 .

[0093] At least one conductor body 2 received in the receiving area 6 of the carrier body 7 can, for example, at least in the state before the carrier body 7 provided with the conductor body 2 is overmolded with the injection-molded material 3, be held in or on the receiving area 6 by means of a holding means 29, in particular on the carrier body side, in a form-fitting and / or material-fitting and / or force-fitting manner. The holding means 29 is in the embodiment according to Figure 6as a one-piece or uniform component of the material forming the carrier body 7. The holding means 29 can, for example, be designed as a latching means and / or as a holding means 29 protruding into and / or adjacent to the receiving space 5 of the receiving area 6 of the carrier body 7. In particular, when the conductor body 2 is inserted, the holding means 29 can, for example, touch the conductor body 2 or apply a clamping and / or prestressing force to it. In this way, the conductor body 2 can be fixed or held in a defined area of ​​the carrier body 7. Consequently, during overmolding and / or during displacement of the assembly consisting of the conductor body 2 and the carrier body 7 into an injection mold, an undesired relative movement of the bodies 2, 7 can be prevented by the holding means 29. The holding means 29 can also hold the conductor body 2 received in the receiving area 6 of the carrier body 7 during deformation orBending of the carrier body 7 and the deformation or bending of the conductor body 2 in the receiving area 6 of the carrier body 7 or prevent the conductor body 2 from moving out.

[0094] During the receiving of the conductor body 2 in or on the receiving area 6 of the carrier body 7 by means of a guide means 32, in particular on the carrier body side (see Figure 6 ), for example, the conductor body 2 can be guided at least partially, in particular completely, into the receiving area 6. In other words, for example, guide means 32 on the carrier body side can be guided into the receiving area 6 of the carrier body 7 at least during part of the feed path of the conductor body 2, or their movement path can be specifically influenced. It is possible to form the holding means 29 and the guide means 32 in one piece, at least in sections, or to form them as a single element that fulfills both functions.

[0095] During the change in the geometric shape of the conductor body 2 and / or the carrier body 7, for example, (a) at least partial, in particular complete, guidance of a relative movement 30, 30' of at least two carrier body partial regions 31, 31' can take place by means of a guide section (not shown), in particular on the carrier body side, and / or (b) a positive and / or non-positive and / or materially bonded connection of at least two connecting sections 33, 33', in particular on the carrier body side. By means of the guide sections, for example on the carrier body side, and / or by means of the connecting sections 33, 33', for example on the carrier body side, guiding and / or connecting or holding functions can take place in connection with the targeted deformation or change in shape and the at least partial fixing of the change in shape by means of the carrier body 7 itself. A guide section can, for example,additionally fulfil the function of a spacing device at least in sections, so that a distance 21 can be generated due to the guide section.

[0096] If the carrier body is manufactured using an injection molding process (e.g., plastic injection molding) or an additive manufacturing process (e.g., CLIP, SLA, etc.), the guiding and / or connecting or holding function can be implemented in a simple and cost-effective manner. Figures 6 and 12Two interlocking connecting sections 33, 33' are visible, which, for example, interlock when the carrier body sections 31, 31' are compressed, thus forming a positive and / or non-positive connection. A first carrier body section 31 can be provided with a first connecting section 33, and a second carrier body section 31' can be provided with a second connecting section 33', wherein, in the compressed state, the interconnected connecting sections 33, 33' prevent springing back or decompression from the compressed state.

[0097] A first conductor body 2 can, for example, be received in a receiving area 6 delimiting a first receiving space 5, and a further conductor body 2 can be received in a receiving area 6 delimiting a further receiving space 5 (not shown). Furthermore, before overmolding at least one carrier body 7 provided with the conductor body 2 with a molding material 3, at least two conductor bodies 2 can optionally be received in different receiving spaces 5 (not shown). This can lead to a component 1 in which different conductor bodies 2 are arranged at different locations. By appropriately controlling or energizing the different conductor bodies 2 via contact means 17 assigned to the respective conductor bodies 2, the electrically and / or magnetically effective functionality of the component 1 can be expanded.

[0098] The invention also relates to a component 1, in particular a component designed as an electrical coil, cf. Figures 2 and 3 This component 1, designed in particular as an electrical coil, can be installed in a vehicle, preferably a motor vehicle. Alternatively or additionally, the component can be used as part of a sensor and / or actuator system, particularly in vehicle construction.

[0099] Finally, the invention comprises a device for producing a component 1 comprising a conductor body 2 and a carrier body 7 according to a method described herein.

[0100] Out of Figure 12the transition of the receiving area 5 from a first to a second axial plane is shown. In this context, the axial plane is a plane running perpendicular to the axis 10 of the spiral shape 9 of the conductor body 2 and / or the carrier body 7, in particular perpendicular to the coil axis. In other words, the at least two axial planes are axially offset from one another. This transition area 22 can be understood as a discontinuity in the spiral shape 9, since in this area, possible deviations from the remaining shape and / or arrangement of the conductor body 2 and / or the carrier body 7 can occur. Figure 12It can be seen that a first connecting section 33 extends from the first axial plane (located at the bottom in the drawing) into the second axial plane and there engages with the second connecting means 33', which is formed by a component of the carrier body 7 lying in the second axial plane, and in particular prevents the carrier body 7 from springing back into an undeformed state, cf. Figure 4 , prevented.

[0101] Certain features of the invention are exemplified again in the following aspects, which do not correspond to the invention defined in the claims: 1. A method for producing a component (1) provided with at least one electrically conductive conductor body (2), wherein the conductor body (2) is at least partially, in particular predominantly, surrounded by a material-to-material and / or form-fitting injection-molded body (4) formed from an injection-molded material (3), comprising the following method steps: receiving the conductor body (2) at least partially in or on a receiving area (6) of a carrier body (7) that delimits a receiving space (5), overmolding the carrier body (7) provided with the conductor body (2) at least partially with the injection-molded material (3) to form a component (1) comprising at least the conductor body (2), the carrier body (7), and the injection-molded body (4).Method according to aspect 1, wherein after and / or during the reception of the conductor body (2) in or on the carrier body (7), a change in the geometric shape of the carrier body (7) occurs at least in sections, wherein with the change in the geometric shape of the carrier body (7), the conductor body (2) undergoes a change in shape, at least in sections, in particular one that is similar or identical to the deformation of the carrier body (7). 3. Method according to aspect 2, wherein the change in shape of the conductor body (2) and / or the carrier body (7) after the arrangement of the conductor body (2) in or on the reception area (6) of the carrier body (7) comprises a deformation such that a body volume (8) formed by the conductor body (2) and / or the carrier body (7) becomes more compact. 4.Method according to aspect 2 or 3, wherein at least one section of the conductor body (2) and / or the support body (7) undergoes a linear and / or rotational movement during its deformation, in particular the conductor body (2) and / or the support body (7) is bent during the deformation. 5. Method according to one of the preceding aspects, wherein the conductor body (2) and / or the support body (7), in particular during or even before its deformation, has at least one spiral shape (9) at least in sections, preferably a spiral shape (9) comprising at least one conical basic shape and / or one cylindrical basic shape and / or one pyramidal basic shape. Particularly preferably, the spiral shape (9) is compressed along an axis (10) of the spiral shape (9) during the deformation of the conductor body (2) and / or the support body (7).Method according to one of the preceding aspects, wherein a first section of the conductor body (2) and / or carrier body (7) has a first, spiral-like, in particular conical or pyramid-like, basic shape (11) and a second section of the conductor body (2) and / or carrier body (7) has a second, spiral-like, in particular conical or pyramid-like, basic shape (12), wherein a tapered region (13) of the first spiral-like basic shape (11) faces or faces away from a tapered region (14) of the second spiral-like basic shape (12).Method according to one of the preceding aspects, wherein after or during the receiving of the conductor body (2) in or on a receiving region (6) of the carrier body (7) in a first injection-molding process, a first injection-molded body is injection-molded onto or onto the conductor body (2) and / or the carrier body (7) at least in sections, in particular completely, and in a second injection-molding process carried out after the first injection-molding process, a second injection-molded body is injection-molded onto or onto the first injection-molded body and / or the conductor body (2) and / or the carrier body (7) at least in sections. 8.Method according to one of the preceding aspects, wherein after or during the receiving of the conductor body (2) in or on a receiving area (6) of the carrier body (7), the carrier body (7) provided with the conductor body (2) is received at least partially, in particular completely, in or on a receiving volume (15) of a base body (16), wherein during the overmolding, in particular by means of the injection-molded material (3), the conductor body (2), the carrier body (7), and the base body (16) are at least partially connected to one another in a materially bonded and / or positively bonded manner.Method according to one of the preceding aspects, wherein at least one contact means (17) is arranged in or on the carrier body (7) and / or in or on the receiving volume of the base body (16) before or during the overmolding, which contact means forms an electrically conductive connection with the conductor body (2). Preferably, at least one contact means region (18) of the contact means (17) is exposed after the overmolding and / or at least one contact means region (18) of the at least one contact means (17) protrudes from the main extension volume of the component (1) after the overmolding. 10. Method according to one of the preceding aspects, wherein at least one iron core and / or electrical component and / or magnetic field-conducting element is arranged in or on the carrier body (7) and / or in or on the receiving volume (15) of the base body (16) before or during the overmolding and is overmolding at least partially with the injection-molded material (3) during the overmolding.Method according to one of the preceding aspects, wherein a conductor body (2) is used which is designed as a stranded wire body (19) and is formed from at least one group of electrically conductive individual wires (38). The stranded wire body (19) preferably has, at least in sections, in particular completely, at least one group of electrically conductive individual wires (38), which are designed as high-frequency stranded wires and / or high-voltage stranded wires and / or as individual wires (38) insulated from one another by an insulating layer (39), in particular by means of an insulating layer (39) designed as a lacquer layer. 12. Method according to one of the preceding aspects, wherein the carrier body (7) and / or the base body (16) is produced, at least in sections, in particular completely, by an injection molding process and / or by an additive manufacturing process. 13.Method according to one of the preceding aspects, wherein the carrier body (7) and / or the base body (16) is formed at least partially, in particular completely, from a plastic, preferably from a thermoplastic. 14. Method according to one of the preceding aspects, wherein the carrier body (7) comprises at least two carrier partial bodies (21, 21'), wherein the carrier partial bodies (21, 21') are assembled before and / or during the reception of the conductor body (2) in or on the reception area (6) of the carrier body (7). 15.Method according to one of the preceding aspects, wherein a carrier body (7) is used which comprises at least two carrier partial bodies (21, 21'), wherein at least two carrier partial bodies (21, 21') each comprise a receiving partial region (22, 22') for at least partially forming the receiving region (6), wherein in particular at least in the state of the overmolded component (1), the at least one conductor body (2) is received in the at least two receiving partial regions (22, 22'). 16. Method according to one of the preceding aspects, wherein a carrier body (7) is used whose receiving region (6) has at least partially an L-shaped and / or a U-shaped and / or a V-shaped and / or a C-shaped and / or a W-shaped cross-sectional geometry, in particular the carrier body (7) has at least predominantly a constant cross-sectional geometry. 17.Method according to one of the preceding aspects, wherein a carrier body (7) is used whose receiving region (6) has a first axial length (24) in a first receiving region section (23) and a second axial length (24') different from the first axial length (24) in a further receiving region section (23'). Preferably, a first receiving region section (23) located closer to the center (25) of the component (1) has a greater axial length (24) than a further receiving region section (23') located further away from the center (25) of the component (1). 18.Method according to one of the preceding aspects, wherein a carrier body (7) is used which, at least in sections, comprises a guide device (28) on a surface (26) of at least one wall section (27) facing away from the receiving area (6), wherein the guide device (28) carries out a targeted guidance of injection material (3) brought to the carrier body (7) during the overmolding. Preferably, at least one guide device (28) on the carrier body side is adapted to the geometric shape of a base body (16) and / or the position and / or orientation of at least one injection opening of an injection molding tool for overmolding the conductor and carrier body (2, 7) received therein, in order to achieve a defined overmolding of the conductor and carrier body (2). 19.Method according to one of the preceding aspects, wherein at least one conductor body (2) received in the receiving area (6) of the carrier body (7) is held in a form-fitting and / or material-fitting and / or force-fitting manner in or on the receiving area (6), at least in the state before the carrier body (7) provided with the conductor body (2) is overmolded with the injection-molded material (3), by means of a holding means (29, 29'), in particular on the carrier body side. 20. Method according to one of the preceding aspects, wherein during the receiving of the conductor body (2) in or on the receiving area (6) of the carrier body (7), the conductor body (2) is guided at least partially, in particular completely, into the receiving area (6) by means of a guide means (32), in particular on the carrier body side. 21.Method according to one of aspects 2 to 20, wherein, during the change in the geometric shape of the conductor body (2) and / or the carrier body (7), a relative movement (30, 30') of at least two carrier body partial regions (31, 31') is guided at least partially, in particular completely, by means of a guide section, in particular on the carrier body side, and / or a positive and / or non-positive and / or material-locking connection of at least two connecting sections (33, 33'), in particular on the carrier body side, is effected. 22. Method according to one of the preceding aspects, wherein a first conductor body (2) is received in a receiving region (6) delimiting a first receiving space (5), and a further conductor body (2) is received in a receiving region (6) delimiting a further receiving space (5), in particular before overmolding at least one carrier body (7) provided with the conductor body (2) with an injection-molded material (3). 23.Component (1), in particular an electrical coil, comprising a conductor body (2) and a carrier body (7), produced by a method according to one of the preceding aspects. 24. Device for producing a component (1) comprising a conductor body (2) and a carrier body (7) by a method according to one of aspects 1 to 22. LIST OF REFERENCE SYMBOLS

[0102] 1 component 22 Transition area 2 Conductor body 23, 23' Recording area section (cross-sectional section) 3 Spray material 4 Spray body 24, 24' axial length of 23.23' 5 recording room 25 Center of 1 6 Recording area 26 Surface of 27 7 carrier body 27, 27' Wall section of 7 8 Body volume of 2 and 7 28 Guide device 9 spiral shape of 2 and / or 7 29 Holding devices 30, 30' Relative motion 10 Axis of 9 31, 31' Carrier body part area / carrier body part 11 first basic form of 2 and / or 7 32 Management tools 12 further basic form of 2 and / or 7 33, 33' Connecting sections 34 collar section 13 tapered area of ​​11 35 channel 14 tapered area of ​​12 36 Main extension volume of 16 15 Recording volume of 16 16 Basic body 37 Recess of 16 17 Contact agent 38 Single wire 18 Contact area of ​​17 39 Insulating layer 19 Stranded wire body 40 Insulating agent 20 Circular ring length of 7 41 Vicinity 21 Distance of 27, 27' 42, 42' Basic form pair

Claims

1. Method for producing a component (1) provided with at least one electrically conductive conductor body (2), wherein the conductor body (2) is surrounded at least in part, in particular predominantly, material-fitting and / or form-fitting by a formed from a spraying material (3) spraying body (4), wherein the following process steps: - receiving the conductor body (2) at least partially in or at a receiving space (5) limiting receiving area (6) of a carrier body (7), - overmolding of the carrier body (7) provided with the conductor body (2) at least partially with the spraying material (3) for forming a component (1) comprising at least the conductor body (2), the carrier body (7) and the spraying body (4), characterized in that After and / or during the reception of the conductor body (2) in or on the carrier body (7), at least in part, a change in the geometric shape of the carrier body (7) takes place, wherein with the change in the geometric shape of the carrier body (7), the conductor body (2) undergoes at least in part a change in shape.

2. Method of claim 1, characterized in that with the change in the geometric shape of the carrier body (7), the conductor body (2) undergoes at least partially a similar or identical change in shape in comparison with the deformation of the carrier body (7), wherein optionally the change in shape of the conductor body (2) and / or the carrier body (7) after the arrangement of the conductor body (2) in or at the receiving region (6) of the carrier body (7) comprises a deformation such that a body volume formed by the conductor body (2) and / or the carrier body (7) (8) becomes more compact.

3. Method of claim 2, characterized in that at least one portion of the conductor body (2) and / or the carrier body (7) undergoes linear and / or rotational movement during its deformation, in particular, the conductor body (2) and / or the carrier body (7) is bent during the deformation.

4. Method according to one of the preceding claims, characterized in that the conductor body (2) and / or the carrier body (7), in particular during or already before its deformation, at least partially at least one spiral-like shape (9), preferably has at least one conical basic shape and / or a cylindrical basic shape-like and / or a pyramidal basic shape-like comprehensive spiral-like shape (9), particularly preferably the spiral-like shape (9) is compressed during the deformation of the conductor body (2) and / or the carrier body (7) along an axis (10) of the spiral-like shape (9).

5. Method according to one of the preceding claims, characterized in that a first section of the conductor body (2) and / or carrier body (7) has a first, spiral-like, in particular cone-like or pyramid-like, basic shape (11) and a second section of the conductor body (2) and / or carrier body (7) has a second, spiral-like, in particular cone-like or pyramid-like, basic shape (12), a tapering region (13) of the first spiral-like basic shape (11) forming a tapering region (13) of the second spiral-like basic shape (12), spiral-like, in particular cone-like or pyramid-like, basic shape (12), wherein a tapering region (13) of the first spiral-like basic shape (11) faces towards or away from a tapering region (14) of the second spiral-like basic shape (12).

6. Method according to one of the preceding claims, characterized in that after or during receiving the conductor body (2) in or on a receiving region (6) of the carrier body (7) in a first injection molding process, a first injection molding body is injected at least partially, in particular completely, on the conductor body (2) and / or the carrier body (7) and in a second injection molding process carried out in time after the first injection molding process on or on the first injection molding body and / or the conductor body (2) and / or the carrier body (7) at least partially, a second injection molding body is injected or injected.

7. Method according to one of the preceding claims, characterized in that a conductor body (2) is used, which is formed as a stranded body (19) and is formed at least from a group of electrically conductive individual wires (38), preferably, the stranded body (19) has at least partially, in particular completely, at least one group of electrically conductive individual wires (38), which are formed as high-frequency strands and / or high-voltage strands and / or as by an insulating layer (39) of each other, in particular by means of an insulating layer formed as a lacquer layer (39), isolated individual wires (38).

8. Method according to one of the preceding claims, characterized in that the carrier body (7) and / or the basic body (16) is produced at least in part, in particular completely, from an injection molding process and / or from an additive manufacturing process, wherein optionally the carrier body (7) and / or the basic body (16) is formed at least in part, in particular completely, from a plastic, preferably from a thermoplastic plastic.

9. Method according to any one of the preceding claims, characterized in that the carrier body (7) comprises at least two carrier part bodies (21, 21'), wherein the carrier part bodies (21, 21') are assembled before and / or during receiving the conductor body (2) in or at the receiving region (6) of the carrier body (7).

10. Method according to any one of the preceding claims, characterized in that a carrier body (7) is used, which comprises at least two carrier part bodies (21, 21'), wherein at least two carrier part bodies (21, 21') each comprise a receiving part region (22, 22') for at least partial formation of the receiving area (6), wherein in particular at least in the state of the molded component (1), which at least one conductor body (2) is received in the at least two receiving part regions (22, 22'); and / or a support body (7) is used whose receiving region (6) has at least in sections an L-shaped and / or a U-shaped and / or a V-shaped and / or a C-shaped and / or a W-shaped cross-sectional geometry, in particular the support body (7) has at least predominantly a constant cross-sectional geometry; and / or a carrier body (7) is used whose receiving region (6) has a first axial length (24) in a first receiving region portion (23) and a second axial length (24) different from the first axial length (24) in a further receiving region portion (23), preferably a first receiving region portion (23) located closer to the center (25) of the component (1) has a greater axial length (24) than a further receiving region portion (23) located farther from the center (25) of the component (1); and / or A carrier body (7) is used which comprises a guide device (28) at least partially on a surface facing away from the receiving region (6) (26) at least of a wall portion (27), wherein the guide device (28) performs a targeted guiding of spray material (3) introduced during the overmolding to the carrier body (7), preferably at least one carrier-side guide device (28) is adapted to the geometric shape of a basic body (16) and / or the position and / or orientation of at least one injection openings of an injection tool for overmolding in this absorbed conductor and carrier body (2, 7) to achieve a defined overmolding of the conductor and carrier body (2).

11. Method according to one of the preceding claims, characterized in that at least one in the receiving region (6) of the carrier body (7) received conductor body (2) at least in the state before the overmolding of the provided with the conductor body (2) carrier body (7) with the spray material (3) by means of a, in particular carrier body-side, holding means (29, 29') positively and / or materially and / or positively held in or on the receiving region (6).

12. Method according to one of the preceding claims, characterized in that during picking up the conductor body (2) in or at the receiving region (6) of the carrier body (7) by means of a, in particular carrier body-side, guide means (32) is carried out at least in part, in particular complete, guiding the conductor body (2) into the receiving region (6).

13. Method according to any one of claims 2 to 12, characterized in that during the change in the geometric shape of the conductor body (2) and / or the carrier body (7) - an at least partial, in particular complete, conducting a relative movement (30, 30') of at least two carrier body portions (31, 31') by means of a, in particular carrier body side, guide portion and / or - a form- and / or a force- and / or material-fitting connection of at least two, in particular carrier body-side, connecting portions (33, 33') takes place.

14. Method according to one of the preceding claims, characterized in that a first conductor body (2) in a first receiving space (5) limiting receiving area (6) and a further conductor body (2) in a further receiving space (5) limiting receiving area (6), in particular before overmolding at least one carrier body (7) provided with the conductor body (2) with a spray material (3), is received.