ELECTRICALLY CONDUCTIVE FILM

Abstract

The invention relates to an electrically conductive film (10) having an electrically nonconductive substrate layer (12), and an electrically conductive metal layer (14) that has a structure produced by material removal and that on a first side is joined, at least in sections, to the substrate layer (12).

Claims

1. An electrically conductive film comprising: an electrically nonconductive substrate layer; and an electrically conductive metal layer that has a structure produced by material removal and that on a first side is joined, at least in sections, to the electrically nonconductive substrate layer; and wherein the electrically conductive metal layer is made of copper, a copper alloy, aluminum, and/or an aluminum alloy.

2. The electrically conductive film according to claim 1, wherein the structure of the electrically conductive metal layer has one or more strip conductors that have at least one bent section.

3. The electrically conductive film according to claim 1, wherein the structure of the electrically conductive metal layer has one or more strip conductors, wherein at least one strip conductor includes multiple strip conductor sections whose strip conductor widths differ from one another.

4. The electrically conductive film according to claim 3, wherein the multiple strip conductor sections of the at least one strip conductor extend in an offset manner and/or in parallel to one another.

5. The electrically conductive film according to claim 3, wherein the strip conductor width of successive strip conductor sections of the at least one strip conductor increases or decreases along the course of the strip conductor.

6. The electrically conductive film according to claim 1, comprising an electrically nonconductive cover layer having a structure that is produced by material removal, wherein the electrically conductive metal layer on a second side is joined, at least in sections, to the electrically nonconductive cover layer

7. The electrically conductive film according to claim 6, wherein the structure of the electrically nonconductive cover layer that is produced by material removal is the same, in its entirety or in sections, as the structure of the electrically conductive metal layer that is produced by material removal.

8. The electrically conductive film according to claim 7, wherein the material of which the electrically nonconductive substrate layer is made has a lower modulus of elasticity than the material of which the electrically nonconductive cover layer is made.

9. The electrically conductive film according to claim 8, wherein the difference between the modulus of elasticity of the material of which the electrically nonconductive substrate layer is made and the modulus of elasticity of the material of which the electrically nonconductive cover layer is made is at least 20 megapascals.

10. The electrically conductive film according to claim 1, wherein the electrically nonconductive substrate layer is made of a thermoplastic elastomer, in particular a thermoplastic polyurethane.

11. The electrically conductive film according to claim 10, wherein the material of which the electrically nonconductive substrate layer is made has a modulus of elasticity in the range of 10 to 100 megapascals.

12. The electrically conductive film according to claim 9, wherein the electrically nonconductive substrate layer and/or the electrically nonconductive cover layer are/is made of a thermoplastic plastic, in particular polyethylene naphthalate or polyethylene terephthalate.

13. The electrically conductive film according to claim 12, wherein the material of which the electrically nonconductive substrate layer and/or the electrically nonconductive cover layer are/is made has a modulus of elasticity in the range of 120 to 1200 megapascals.

14. (canceled)

15. The electrically conductive film according to claim 1, comprising an electrically nonconductive supporting layer that is joined to the electrically conductive metal layer or to the side of the electrically nonconductive substrate layer opposite from the metal layer.

16. The electrically conductive film according to claim 15, wherein the electrically nonconductive supporting layer is made of a thermoplastic elastomer, in particular a thermoplastic polyurethane.

17. The electrically conductive film ac cording to claim 16, wherein the adhesion of the electrically nonconductive supporting layer to the electrically nonconductive substrate layer or to the electrically conductive metal layer allows damage-free detachment of the electrically nonconductive supporting layer from the electrically nonconductive substrate layer or the electrically conductive metal layer.

18. An electrical heating device having one or more electrically conductive films comprising: an electrically nonconductive substrate layer; and an electrically conductive metal layer that has a structure produced by material removal and that on a first side is joined, at least in sections, to the electrically nonconductive substrate layer; wherein the electrically conductive metal layer is made of copper, a copper alloy, aluminum, and/or an aluminum alloy.

19. The electrical heating device according to claim 18, wherein at least one strip conductor of the electrically conductive metal layer of an electrically conductive film has one or more strip conductors designed as a heating conductor and/or extends in a meandering manner in sections.

20. A cell contacting unit for a battery, in particular a vehicle battery, comprising: one or more electrically conductive films comprising: an electrically nonconductive substrate layer; and an electrically conductive metal layer that has a structure produced by material removal and that on a first side is joined, at least in sections, to the electrically nonconductive substrate layer; wherein the electrically conductive metal layer is made of copper, a copper alloy, aluminum, and/or an aluminum alloy.

21. The cell contacting unit according to claim 20, wherein at least one of the electrically conductive films has contacting sections that are configured to be electroconductively connected to contact poles of unit cells.

22. A cell voltage tap for a battery, in particular a vehicle battery, comprising: one or more electrically conductive films comprising: an electrically nonconductive substrate layer; and an electrically conductive metal layer that has a structure produced by material removal and that on a first side is joined, at least in sections, to the electrically nonconductive substrate layer; wherein the electrically conductive metal layer is made of copper, a copper alloy, aluminum, and/or an aluminum alloy.

23. The cell voltage tap according to claim 22, wherein at least one electrically of the conductive films has contacting sections that are configured to be electroconductively connected to contact poles of unit cells.

24. A manufacturing method for an electrically conductive film, comprising the steps: providing a film that has at least one electrically nonconductive substrate layer and at least one electrically conductive metal layer and producing a structure of the electrically conductive metal layer by means of a material-removing process, in particular a machining process; wherein during production of the structure of the metal layer, one or more strip conductors are created which have at least one bent section; and wherein the electrically conductive metal layer is made of copper, a copper alloy, aluminum, and/or an aluminum alloy.

25. The manufacturing method according to claim 24, wherein the provided film has an electrically nonconductive cover layer, wherein the method includes the step of: producing a structure of the electrically nonconductive cover layer by means of a material-removing process, in particular a machining process.

26. The manufacturing method according to claim 25, wherein the production of the structure of the electrically conductive metal layer and the production of the structure of the electrically nonconductive cover layer take place at the same time, and/or the produced structure of the electrically nonconductive cover layer is the same, in its entirety or in sections, as the produced structure of the electrically conductive metal layer.

Description

[0039] Preferred embodiments of the invention are explained and described in greater detail below with reference to the appended drawings, which show the following:

[0040] FIG. 1 shows the manufacture of an electrically conductive film according to the invention in a schematic illustration;

[0041] FIG. 2 shows the manufacture of an electrically conductive film according to the invention in a schematic illustration;

[0042] FIG. 3 shows the manufacture of an electrically conductive film according to the invention in a schematic illustration;

[0043] FIG. 4 shows the manufacture of an electrically conductive film according to the invention in a schematic illustration;

[0044] FIG. 5 shows one exemplary embodiment of the electrical heating device according to the invention in a schematic illustration;

[0045] FIG. 6 shows one exemplary embodiment of the cell contacting unit according to the invention in a schematic illustration;

[0046] FIG. 7 shows one exemplary embodiment of the manufacturing method according to the invention in a block diagram;

[0047] FIG. 8 shows the width profile of multiple strip conductors of a metal layer of an electrically conductive film according to the invention; and

[0048] FIG. 9 shows one exemplary embodiment of the electrical heating device according to the invention in a schematic illustration.

[0049] FIG. 1 on the left side shows an electrically conductive film 10 having an electrically nonconductive substrate layer 12 and an electrically conductive metal layer 14.

[0050] The substrate layer 12 is made of a material that has a modulus of elasticity in the range of 120 to 1200 megapascals. For example, the substrate layer 12 may be made of polyethylene naphthalate or polyethylene terephthalate.

[0051] The metal layer 14 is made of copper and aluminum, for example copper-clad aluminum, and on a first side is joined to the substrate layer 12.

[0052] The right side of FIG. 1 shows the film 10 illustrated on the left side of FIG. 1, after material removal from the metal layer 14 has taken place. The produced structure of the metal layer 14 has a strip conductor 20 having a bent section (concealed).

[0053] FIG. 2 on the left side shows an electrically conductive film 10 having an electrically nonconductive substrate layer 12, an electrically conductive metal layer 14, and an electrically nonconductive cover layer 16.

[0054] The substrate layer 12 is made of a material that has a modulus of elasticity in the range of 120 to 1200 megapascals. For example, the substrate layer 12 may be made of polyethylene naphthalate or polyethylene terephthalate.

[0055] The metal layer 14 is made of copper and aluminum, for example copper-clad aluminum, and on a first side is joined to the substrate layer 12 and on a second side is joined to the cover layer 16.

[0056] The cover layer 16 is made of a material that has a modulus of elasticity in the range of 120 to 1200 megapascals. For example, the cover layer 16 may be made of polyethylene naphthalate or polyethylene terephthalate.

[0057] The right side of FIG. 2 shows the film 10 illustrated on the left side of FIG. 2, after material removal from the metal layer 14 and the cover layer 16 has taken place. The produced structure of the metal layer 14 is different from the produced structure of the cover layer 16.

[0058] FIG. 3 on the left side shows an electrically conductive film 10 having an electrically nonconductive substrate layer 12, an electrically conductive metal layer 14, an electrically nonconductive cover layer 16, and an electrically nonconductive supporting layer 18.

[0059] The substrate layer 12 is made of a material that has a modulus of elasticity in the range of 10 to 100 megapascals. For example, the substrate layer 12 may be made of a thermoplastic elastomer such as a thermoplastic polyurethane.

[0060] The metal layer 14 is made of copper and aluminum, for example copper-clad aluminum, and on a first side is joined to the substrate layer 12 and on a second side is joined to the cover layer 16.

[0061] The cover layer 16 is made of a material that has a modulus of elasticity in the range of 120 to 1200 megapascals. For example, the cover layer 16 may be made of polyethylene naphthalate or polyethylene terephthalate. The material of which the substrate layer 12 is made thus has a lower modulus of elasticity than the material of which the cover layer 16 is made. In addition, the difference between the modulus of elasticity of the material of which the substrate layer 12 is made and the modulus of elasticity of the material of the material of which the cover layer 16 is made is greater than 20 megapascals.

[0062] The supporting layer 18 is made of a material that has a modulus of elasticity in the range of 120 to 1200 megapascals. For example, the supporting layer 18 may be made of polyethylene naphthalate or polyethylene terephthalate, wherein the material thickness of the supporting layer 18 is greater than the respective material thicknesses of the other layers 12, 14, 16. In addition, the supporting layer 18 is joined to the side of the substrate layer 12 opposite from the metal layer 14, wherein the adhesion of the supporting layer 18 to the substrate layer 12 allows damage-free detachment of the supporting layer 18 from the substrate layer 12.

[0063] The right side of FIG. 3 shows the film 10 illustrated on the left side of FIG. 3, after material removal from the metal layer 14 and the cover layer 16 on the one hand, and detachment of the supporting layer 18 from the substrate layer 12 on the other hand, have taken place. The produced structure of the metal layer 14 differs from the produced structure of the cover layer 16. However, it is also conceivable for the material removal to take place in such a way that the produced structure of the cover layer 16 is the same, in its entirety or in sections, as the produced structure of the metal layer 14.

[0064] FIG. 4 on the left side shows an electrically conductive film 10 having an electrically nonconductive substrate layer 12, an electrically conductive metal layer 14, and an electrically nonconductive supporting layer 18.

[0065] The substrate layer 12 is made of a material that has a modulus of elasticity in the range of 120 to 1200 megapascals. For example, the substrate layer 12 may be made of polyethylene naphthalate or polyethylene terephthalate.

[0066] The metal layer 14 is made of copper and aluminum, for example copper-clad aluminum, and on a first side is joined to the substrate layer 12.

[0067] The supporting layer 18 is made of a material that has a modulus of elasticity in the range of 120 to 1200 megapascals. For example, the supporting layer 18 may be made of polyethylene naphthalate or polyethylene terephthalate, wherein the material thickness of the supporting layer 18 is greater than the respective material thicknesses of the other layers 12, 14. In addition, the supporting layer 18 is joined to the metal layer 14, wherein the adhesion of the supporting layer 18 to the metal layer 14 allows damage-free detachment of the supporting layer 18 from the metal layer 14.

[0068] The right side of FIG. 4 shows the film 10 illustrated on the left side of FIG. 4, after material removal from the metal layer 14 and the substrate layer 12 on the one hand, and detachment of the supporting layer 18 from the metal layer 14 on the other hand, have taken place. The produced structure of the metal layer 14 and the produced structure of the substrate layer 12 are the same.

[0069] FIG. 5 shows an electrical heating device 100 having an electrically conductive film 10. The electrically conductive film 10 has an electrically nonconductive substrate layer 12 and an electrically conductive metal layer 14.

[0070] The metal layer 14 includes a structure that is produced by material removal, and on a first side is joined to the substrate layer 12. The structure of the metal layer 14 has a strip conductor 20 that is designed as a heating conductor and that in the sections 24a-24e extends in a meandering manner and thus includes a plurality of bent sections 22. A contact section 26a, 26b is situated in each case at the ends of the heating conductor, wherein the heating conductor of the heating device 100 is suppliable with electrical energy via the contacting sections 26a, 26b.

[0071] FIG. 6 shows a cell contacting unit 200 for a battery, namely, a vehicle battery. The cell contacting unit 200 has an electrically conductive film 10 that includes an electrically nonconductive substrate layer 12 and an electrically conductive metal layer 14.

[0072] The metal layer 14 has a structure that is produced by material removal, wherein the structure of the metal layer 14 includes multiple strip conductors 20 that have a plurality of bent sections 22.

[0073] The electrically conductive film 10 also includes contacting sections 26a-26d that are electroconductively connected to contact poles 204a-204d of unit cells 202a-202d.

[0074] FIG. 7 shows a manufacturing method for an electrically conductive film 10. The manufacturing method is initiated by the following step:

[0075] 300) providing a film 10 having an electrically nonconductive substrate layer 12, an electrically conductive metal layer 14, and an electrically nonconductive cover layer 16.

[0076] After the film 10 has been provided, the following steps may be carried out:

[0077] 302) producing a structure of the metal layer 14 by means of a machining process; and

[0078] 308) producing a structure of the cover layer 16 by means of a machining process.

[0079] During production of the structure of the metal layer 14, multiple strip conductors 20 are created, wherein the production of the structure of the metal layer 14 by means of a machining process comprises the following two steps:

[0080] 304) producing material elevations in the metal layer 14 by means of an embossing roller; and

[0081] 306) removing the material elevations in the metal layer 14 by means of a milling wheel.

[0082] The product ion of the structure of the cover layer 16 by means of a machining process analogously comprises the following two steps:

[0083] 310) producing material elevations in the cover layer 16 by means of the embossing roller; and

[0084] 312) removing the material elevations in the cover layer 16 by means of the milling wheel.

[0085] The production of the structure of the metal layer 14 and the production of the structure of the cover layer 16 take place at the same time, namely, by the embossing roller producing sufficiently projecting material elevations in the metal layer 14 and the cover layer 16 so that the material elevations in the metal layer 14 and the cover layer 16 produced by the embossing roller may at the same time be removed by the milling wheel. The produced structure of the cover layer 16 is thus the same as the produced structure of the metal layer 14. Alternatively, however, by using an embossing roller that has embossing sections with different heights, it is also possible to produce electrically conductive films 10 whose various layers have different structural patterns.

[0086] FIG. 8 shows the structure of multiple strip conductors 20 of a metal layer 14. All strip conductors 20 in each case have multiple strip conductor sections 28a-28e having strip conductor widths B1-B5 that are different from one another. The strip conductor sections 28a-28e of the strip conductors 20 extend in an offset manner and in parallel to one another. The strip conductor width B1-B5 of successive strip conductor sections 28a-28e increases along the course of the strip conductor. The strip conductor section 28a has a strip conductor width B1 of 4.2 millimeters. The strip conductor section 28b has a strip conductor width B2 of 3.8 millimeters. The strip conductor section 28c has a strip conductor width B3 of 3.2 millimeters. The strip conductor section 28d has a strip conductor width B4 of 2.3 millimeters. The strip conductor section 28e likewise has a strip conductor width B5 of 2.3 millimeters. Bent transition sections 30a-30d are situated between the strip conductor sections 28a-28e. The ends of the individual strip conductors 20 are positioned on one side, laterally offset relative to one another.

[0087] FIG. 9 shows an electrical heating device 100 having an electrically conductive film 10. The electrically conductive film 10 has an electrically nonconductive substrate layer 12 and an electrically conductive metal layer 14.

[0088] The metal layer 14 includes a structure that is produced by material removal, and on a first side is joined to the substrate layer 12. The structure of the metal layer 14 has two strip conductors 20 that are designed as heating conductors, and that extend continuously in a meandering manner and thus include a plurality of bent heating conductor sections 22. The two heating conductors that extend in a meandering manner each have a nonuniformly bent design in sections, wherein the proportion of bent heating conductor sections is greater than 90%. Contacting sections 26a, 26b are situated on the respective ends of the heating conductors, wherein the heating conductors of the heating device 100 are suppliable with electrical energy via the contacting sections 26a, 26b.

[0089] The invention preferably relates to a heating element having an elastically and/or plastically deformable substrate, a strip conductor that is situated on the substrate, and a cover layer whose base area is congruent with the base area of the strip conductor, and whose tensile strength is at least twice that of the strip conductor.

[0090] The invention further preferably relates to a connection conductor having at least one machined electrically nonconductive nonconductor zone, and at least one strip conductor that has a bent course, at least in sections, within the conductor level.

LIST OF REFERENCE NUMERALS

[0091] 10 electrically conductive film

[0092] 12 substrate layer

[0093] 14 metal layer

[0094] 16 cover layer

[0095] 18 supporting layer

[0096] 20 strip conductor

[0097] 22 bent sections

[0098] 24a-24e meandering sections

[0099] 26a-26d contacting sections

[0100] 28a-28e strip conductor sections

[0101] 30a-30d transition sections

[0102] 100 electrical heating device

[0103] 200 cell contacting unit

[0104] 202a-202d unit cells

[0105] 204a-204d contact poles

[0106] 300-312 method steps

[0107] B1-B5 strip conductor widths