Method for producing a connecting device

Abstract

A method for producing a connecting device for connecting films with conductor tracks includes the steps of laying a first film with conductor tracks onto a forming die, applying a first lower shell of a plastic material onto a first end portion of the forming die, producing a cut-out and shifting the first film so that the cut-out lies completely on the first lower shell, applying upper conductor tracks of a conductive material onto the first lower shell so that the upper conductor tracks overlap with the conductor tracks of the first film, and applying a first upper shell of a plastic material onto the first lower shell so that the first film, the first lower shell and the first upper shell connect together by substance bonding to form a first connector. In this way, an integral connector can be provided on each film.

Claims

1. A method for producing a connecting device for connecting films with conductor tracks, comprising: laying a first film with a first arrangement of conductor tracks onto a first portion of a forming die; applying a first lower shell of a plastic material onto a first end portion of the forming die adjoining the first portion; producing a cut-out open towards the first end portion on the first film; shifting the first film so that the cut-out lies completely on the first lower shell; applying upper conductor tracks of a conductive material onto the first lower shell so that the upper conductor tracks overlap with the conductor tracks of the first film; and applying a first upper shell of a plastic material onto the first lower shell so that the first film, the first lower shell and the first upper shell connect together by substance bonding to form a first connector.

2. The method according to claim 1, further comprising: laying a second film with a second arrangement of conductor tracks onto a second portion of the forming die; applying a second lower shell of a plastic material onto a second end portion of the forming die adjoining the second portion; producing a cut-out open towards the second end portion on the second film; shifting the second film so that the cut-out lies completely on the second lower shell; applying upper conductor tracks of a conductive material onto the second lower shell so that the upper conductor tracks overlap with the conductor tracks of the second film; and applying a second upper shell of a plastic material onto the second lower shell so that the second film, the second lower shell and the second upper shell connect together by substance bonding to form a second connector, which is formed so as to be complementary to the first connector such that the first connector and the second connector are configured to be connected together mechanically and electrically.

3. The method according to claim 1, wherein the applying of the lower shell and/or the upper shell step comprises performing an additive layer manufacturing process.

4. The method according to claim 1, wherein the cut-out has a smaller surface extension than the first lower shell.

5. The method according to claim 1, wherein the cut-out is formed to be rectangular and has a smaller width and smaller depth than the first lower shell.

6. The method according to claim 1, further comprising producing at least one opening with a contour which is spaced from edges of the first film.

7. The method according to claim 6, wherein the producing of at least one opening step comprises producing at least two openings which are adjacent to two mutually opposing edges of the cut-out.

8. The method according to claim 1, wherein the applying of upper conductor tracks step comprises performing an additive layer manufacturing process.

9. The method according to claim 1, wherein the applying of the lower shell and/or the upper shell step further comprises integrating at least one latching means.

10. The method according to claim 1, wherein the applying of upper conductor tracks step further comprises producing a contact portion to form a connection with another contact portion.

11. The method according to claim 1, wherein the first lower shell and the first upper shell form a protrusion at which the upper conductor tracks of the first film end.

12. The method according to claim 2, wherein the first lower shell and the first upper shell form a protrusion at which the upper conductor tracks of the first film end, and wherein the second lower shell and the second upper shell enclose a recess into which the protrusion is configured to be inserted and in which the upper conductor tracks of the second film end.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further features, advantages and possible applications of the present invention arise from the following description of the exemplary embodiments and from the figures. All features described and/or shown in the figures, alone and in arbitrary combination, form the subject of the invention, irrespective of their combination in the individual claims or back references. In the figures, the same reference signs designate the same or similar objects.

(2) FIGS. 1 to 10 show individual working steps for performance of the method according to an aspect of the invention.

(3) FIG. 11 shows a system for production of a line system.

(4) FIG. 12 shows an aircraft with a line system.

DETAILED DESCRIPTION

(5) The following FIGS. 1 to 10 show individual working steps of the method according to an aspect of the invention. At the same time, suitable tools are shown which may execute the method according to an aspect of the invention.

(6) FIG. 1 shows a forming die 2 with the first forming die half 4 and a second forming die half 6, which for example are laid flush against each other. In the further figures, for the sake of simplicity, only the first forming die half 4 is depicted. Method steps executed thereon may also be executed similarly on the second forming die half 6.

(7) Firstly, a first film 8 is laid on a first portion 10 of the forming die 2, wherein the first film 8 has an arrangement 12 of conductor tracks 14. A first end portion 16 of the forming die 2 however remains free. Here, a first device 18 is arranged for producing a depression, as will be explained in more detail in the following figures. The first film 8 adjoins this first device 18.

(8) Furthermore, a second film 20 is laid on a second portion 22 of the forming die 2 and adjoins a second device 24 for producing a depression, which is arranged in the second end portion 26. The second film 20 has a second arrangement 28 of conductor tracks 30 which are to be connected to the conductor tracks 14 on the first film 8.

(9) FIG. 2 shows, in a slightly enlarged view, the first forming die half 4 with the first film 8 arranged thereon and adjoining the first end portion 16. The first device 18 for producing a depression comprises compressible or retractable elements 32 which are movable in a direction perpendicular to an extension plane of the first film 8 or a first surface 34. In this way, a defined depression 36 can be produced, as shown in FIG. 3. It should be noted here that the depression 36 does not extend over the entire first end portion 16 but merely over a partial portion.

(10) FIG. 4 shows a first device 38 for applying a plastic material in the depression 36. As an example, a robot arm 40 is used here which, at a free end 42, is provided with a delivery device 44 which can conduct plastic into the depression 36. The plastic could for example be provided on a coil 46 in the form of a strip-like plastic material 48 which is heated in the delivery head 44 and conducted into the depression 36 in liquid or paste form. Individual strips may be deposited by the robot arm 40, which are arranged parallel to each other or in a specific pattern. The aim is to fill the depression 36 completely with the plastic material and thereby produce a first lower shell 49.

(11) As FIG. 5 shows, a cut-out 50 is then produced in the first film 8. The cut-out is for example rectangular and open towards the first end portion 16. Adjacent to this, two openings 52 are arranged which are spaced from the cut-out 50. For example, the arrangement of cut-out 50 and openings 52 is symmetrical. For example, the cut-out and the openings 52 are produced by a physical cutting device 54 implemented in the form of a laser cutting device arranged on a robot arm 56. This could comprise an external laser 58 which is guided to an exit lens via optical fibres 60. The robot arm 56 may be the same robot arm as the robot arm 40 shown in FIG. 4.

(12) As FIG. 6 shows, the first film 8 is shifted onto the depression 36 so that the cut-out 50 lies completely on the depression 36 or on the first lower shell 49. Then upper conductor tracks 62 of a conductive material are applied to the first lower shell 49 so that they substantially completely cover the first end portion 16 and overlap at least in regions with the conductor tracks 14 of the first film 8. The upper conductor tracks 62 consequently complement the conductor tracks 14 of the first film 8 in order to create a contact portion 64.

(13) It is noted here that the first film 8 does not completely cover the entire first end portion 16 but has a spacing from an end edge 66 of the first end portion 16, which means that the upper conductor tracks 62 are configured such that their contact portion 64 extends from the first film 8. The application of the upper conductor tracks 62 may take place by an additive process. For this, another robot arm 68 is shown which may correspond to the robot arm 40 or the robot arm 56. A store 70 for providing a conductive material is here connected with a delivery head 72 which applies the conductive material in layers onto the lower shell. This material may for example comprise a meltable plastic or a hardenable binder with conductive particles contained therein.

(14) As shown in FIG. 7, then the device 38 may apply a first upper shell 74 which is oriented and formed so as to correspond to the lower shell. In this way, the first film 8, the conductor tracks 14 and 62, and the lower shell form an integral first connector 76. For example, latching means 78 are arranged on a side of the first upper shell 74 facing away from the first film 8.

(15) FIG. 8 shows that the forming die 2 may also be used to produce a second connector 80 which is integrally connected to the second film 20. Accordingly, a second lower shell 81 and a second upper shell 83 are formed here. The first connector 76 and the second connector 80 are designed to be complementary to each other. Whereas the first connector 76 has a protrusion 82, the second connector 80 has a depression 84.

(16) Also, the individual partial depictions, for example detail depiction A, show that latching means 86 are also arranged in the depression 84 and correspond to the latching means 78 of the first connector 76. The second connector 80 also has tabs 88 which face away from each other and are arranged on a side facing away from the recess 84, and which can be gripped and pressed in the manner of pincers in order to enlarge the recess 84, move the latching means 86 apart, and release a connection to the first connector 76.

(17) Furthermore, an upper conductor track 90 can be seen on an inner end of the recess 84, which may come into contact with the first contact portion 64. Accordingly, this is a second contact portion 90 corresponding thereto.

(18) FIG. 9 shows the first connector 76 and a second connector 80 which create a mechanical and electrical connection. It is evident that the second connector 80 is configured such that it completely covers the first connector 76. The two films 8 and 20, with their conductor tracks 14 and connectors 76 and 80, form a line system 92.

(19) FIG. 10 furthermore indicates that the device 18 for producing a depression can also easily be adapted to other arrangements of conductor tracks 14. Here for example, a larger depression 36 is shown which is designed for a total of six conductor tracks 14. Evidently, this depiction is merely diagrammatic, and depression 36 may also be produced for significantly more or also fewer conductor tracks 14.

(20) FIG. 11 shows as an example that a system 94 may be used which may contain all three robot arms 40, 56 and 68, each with connected delivery heads and material stores. In this way, connectors and line systems can be produced very rapidly without the need for complex tool exchange.

(21) FIG. 12 furthermore shows an aircraft 96 which is equipped with at least one line system 92 on an equipment object (not shown).

(22) In addition, it is pointed out that the term “comprising” does not exclude other elements or steps, and the terms “one” or “a” do not exclude a plurality. It is furthermore pointed out that features described with reference to one of the above-mentioned exemplary embodiments may also be used in combination with other features of other exemplary embodiments described above. Reference signs in the claims should not be regarded as a restriction.

(23) While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, the terms “a” or “one” do not exclude a plural number, and the term “or” means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.