METHOD FOR PRODUCING AN ELECTRIC COMPONENT CARRIER FOR AUTOMOBILE APPLICATIONS

Abstract

A method for producing an electric component carrier for automobile applications, in particular an electric component carrier for a lock. The electric component carrier is equipped with a conductive track arrangement and a base plate, which supports the conductive track. In the initial state, the conductive track arrangement has one or more separation points depending upon the required mode of operation in the operational state. According to the invention, the conductive track arrangement in the initial state is coated at least partially with a casting compound by means of injection molding and then the separation point is introduced into the free region.

Claims

1. A method for producing an electric component carrier for automobile applications, in particular an electric component carrier for a lock, with a conductive track arrangement and a base plate which supports the conductive track arrangement, whereby the conductive track arrangement in the initial state has one or more separation points depending upon the required mode of operation in the operational state, wherein the conductive track arrangement in the initial state is at least partially coated with a casting compound, in particular plastic, and that the separation point is then introduced into the free region.

2. The method according to claim 1, wherein the partially coated conductive track arrangement that is also equipped with the separation point is then connected to the base plate.

3. The method according to claim 1, wherein the partially coated conductive track arrangement that is also equipped with the separation point is fully coated with the casting compound as the preliminary molding, preferably with simultaneous definition of the base plate.

4. The method according to claim 1, wherein the conductive track arrangement in the initial state is stamped out of a sheet metal or metal film.

5. The method according to claim 1, wherein the respective separation point is introduced into the conductive track arrangement by means of a stamping/bending process.

6. The method according to claim 5, wherein the respective separation point (2) is stamped free.

7. The method according to claim 1, wherein the conductive track arrangement, depending on the mode of operation, is equipped with at least one contact connector in addition to the separation point, that has been introduced into an opening to connect switching means for example.

8. The method according to claim 1, wherein the conductive track arrangement is initially equipped with the electrical/electronic constructional elements and then partially coated, and then finally equipped with at least the one separation point and if necessary the contact connector and optional additional electric/electronic constructional elements, and then finally fully coated.

9. The method according to claim 1, wherein the conductive track arrangement is initially partially coated and then finally equipped with at least the one separation point and if necessary the contact connector, then fully coated and finally equipped with the electric/electronic constructional elements.

10. The method according to claim 1, wherein the conductive track arrangement is initially partially coated in a first injection molding tool and then finally fully coated in another second injection molding tool.

11. An electric component carrier for automobile applications, in particular an electric component carrier, preferably manufactured with recourse to the process according to claim 1, with a conductive track arrangement equipped with electric/electronic constructional elements, and with a base plate which supports the conductive track arrangement, whereby the conductive track arrangement in an initial state has at least one introduced separation point depending upon the required mode of operation in the operational state, wherein the separation point is introduced into a free region of the conductive track arrangement that in the initial state is at least partially coated with casting compound.

Description

[0020] Hereinafter, the invention is explained in further detail on the basis of a drawing which only depicts an execution example.

[0021] FIG. 1 shows an electric component carrier in its first variant, whilst FIG. 2 shows a variant deviating from FIG. 1 of the relevant electric component carrier.

[0022] The figures show an electric component carrier, more specifically, an electric component carrier for a lock that is suitable and intended for arrangement and attachment in a motor vehicle door lock. The relevant motor vehicle door lock is a so-called electric lock, in other words, one where a mandatory locking mechanism is usually opened mechanically. In fact, in this case, a distinction can be made between two basic variants, namely the semi-electric variant illustrated in FIG. 1 and the fully electric variant illustrated within the context of FIG. 2.

[0023] For the semi-electric mode of operation, the procedure for example is that the locking mechanism is only opened electrically, whilst the other activation elements in the motor vehicle door lock primarily operate mechanically. The fully electric variant is usually characterized in that all functional states of the motor vehicle door lock are defined by separate motors and that mechanical activation elements are provided for reasons of redundancy if need be. In any case, the individual conductive track arrangements 1 and those illustrated in FIGS. 1 and 2 in essence only differ in that starting from a conductive track arrangement 1 in the initial state, one or more separation points 2 have been introduced into the operational state depending on the desired mode of operation.

[0024] The initial state of the conductive track arrangement 1 corresponds to the respective conductive tracks of the conductive track arrangement 1 running continuously and are not equipped with the separation point 2 illustrated as an example in FIG. 1. Furthermore, possible and additionally attached contact connectors 3 are missing from the conductive track arrangement 1 in the initial state, as can be seen in the relevant FIGS. 1 and 2. The relevant contact connectors 3 are respectively attached to at least one opening of the conductive track arrangement 1 and are used for example to connect switching means. The switching means can for instance include a switch that is used to initiate a central locking system or anti-theft device. Furthermore, with the aid of the switching means it is possible to query switching states such as Rotary latch closed or Internal operating lever applied. Naturally, this is overall only an example.

[0025] The conductive track arrangement 1 is supported by a base plate 4. The base plate 4 can be a carrier plate or a supporting element that, together with the conductive track arrangement 1 and with the attached electric/electronic constructional elements 5, is accommodated and placed in a lock housing of a motor vehicle door lock which is not illustrated. In principle, the conductive track arrangement 1 including the base plate 4, which supports the conductive track arrangement 1 can also be used in a different housing, for example in an actuating drive housing to drive a sliding door, window lifter, mirror, car seat, etc. This is not depicted in detail. Furthermore, within the scope of the invention, there is the possibility that the base plate 4, which supports the conductive track arrangement 1 is formed as a component of the relevant housing, for example illustrates or can illustrate a component of the lock housing for a motor vehicle door lock.

[0026] As previously explained, the conductive track arrangement 1 serves primarily to accommodate and bond electric/electronic constructional elements 5. The conductive track arrangement 1 is therefore usually equipped at one end with a contact element, for example a plug or socket so that the electric/electronic constructional elements 5 are energized via the conductive track arrangement 1. In addition to the resistances illustrated in FIG. 1 as electronic constructional elements 5, a strip conductor bridge can also be included here, as illustrated in FIG. 2. The electric/electronic constructional elements 5 also include switches, as depicted in FIGS. 1 and 2 for both design models.

[0027] To manufacture the electric component carrier thus executed, the conductive track arrangement 1 in the initial state is initially equipped with one or several separation points 2. The initial state of the conductive track arrangement is mainly illustrated in FIG. 2, since all conductive tracks of the conductive track arrangement 1 run continuously. In contrast, with the conductive track arrangement 1, within the scope of FIG. 1, a separation point 2 is introduced and provided, which interrupts the associated conductive track.

[0028] The conductive track in detail is a conductor strip of a specified width. The material thickness of the conductor strip is usually determined by the material thickness of a sheet metal or metal film, out of which the conductive track arrangement 1 is stamped in the initial state. This means that the conductive track arrangement 1 is a leadframe in the exemplary embodiment. This is of course not restrictive.

[0029] In order to now be able to introduce the one or more separation points 2 and to prevent damage to the conductive track arrangement 1 and to the electric/electronic constructional elements 5 that are already on it or are already attached to it, the conductive track arrangement 1 in the initial state is at least partially coated with a casting compound 6, as illustrated in FIG. 1. This means that the conductive track arrangement 1 in the initial state is initially equipped with the electric/electronic constructional elements 5, at least in the region that is consequently covered by the partial coating 6. The partial coating 6 ensures that the conductive track arrangement 1 is overall stabilized since only a free region 7 is left here that is not covered by the partial coating 6. The free region 7 is much smaller in size than the whole conductive track arrangement 1, it may for example be 10% to 30% maximum of the region covered by the conductive track arrangement 1.

[0030] In a further advantageous embodiment, the conductive track arrangement is initially partially coated and then finally equipped with at least the one separation point and if necessary the contact connector, then fully coated and finally equipped with the electric/electronic constructional elements. Optionally, after placing the electric/electronic constructional elements, a liquid casting compound can be applied as a seal.

[0031] The one, or more separation points 2 can thus be introduced without problems into the relevant free region 7. For the conductive track arrangement 1 is mechanically stabilized and also protected through the partial coating 6. In order to now introduce the one, or more separation points 2, the respective separation point 2 is generally introduced into the conductive track arrangement 2 by means of a stamping/bending process. According to the exemplary embodiment, the respective separation point 2 is stamped free. For this purpose, the conductive track arrangement 1 equipped with partial coating 6 is placed in a stamping tool with one or several stamps and opposite die with the openings associated with the stamps. The stamps are mostly stamp fingers that can can be individually stamped for the stamping process. The possibility therefore exists of being able to simultaneously introduce several separation points 2 at different sites into the conductive track arrangement 1 in the free region 7. With this process, the conductive track arrangement 1 is neither damaged nor bent in any way as the partial coating 6 ensures the desired stabilization and protection of the conductive track arrangement 1.

[0032] The size and expansion of the respective stamp or stamp finger is hereby designed in such a way that the respectively separated conductor strip is completely separated over its entire width and consequently stamped free.

[0033] Thus, through the corresponding application of the individual stamps or stamp fingers, the stamping tool can be adapted to the number and position of the separation points 2 to be introduced into the conductive track arrangement 1 in the initial state and subsequently to the desired mode of operation in the finished operational state.

[0034] The conductive track arrangement 1 with the partial coating 6 and the introduced separation points 2 can now also be equipped with the one or more contact connectors 3 to connect the switching means, as illustrated in FIGS. 1 and 2. There is also the possibility to attach additional electric/electronic constructional elements 5 if necessary in the free region 7 and to connect or bond with the conductive track arrangement 1. Finally, the partially coated conductive track arrangement 1 that is also equipped with separation point 2 is then connected to the base plate 4. For this purpose and according to a preferred execution form, the conductive track arrangement 1 that has the partial coating 6 and the respective separation point 2 is fully coated with the respective casting compound as the preliminary molding with simultaneous definition of the base plate 4.

[0035] The casting compound is generally plastic and in particular thermoplastic plastic. In this instance you usually resort to one and the same plastic for both partial coating 6 and full coating, even though it is of course possible to also work with different plastics. In any case, the relevant preliminary molding is inserted into a corresponding injection molding tool and fully coated. This injection molding tool is a second injection molding tool, since the partial coating 6 was previously undertaken and executed in a first injection molding tool.

[0036] With the full coating thus executed in the second injection molding tool, the base plate 4, which supports the conductive track arrangement 1 is defined at the same time in an advantageous approach and embodiment of the invention. This means that with the aid of the plastic for the full coating, it is not only the conductive track arrangement with the separation points 2, the contact connectors 3 and the electric/electronic constructional elements 5 bonded to it, that are sealed, but this process allows the base plate 4 to be manufactured and defined at the same time. The base plate 4 can be a carrier plate or a supporting element, with the aid of which the conductive track arrangement 1 is placed into a housing. It is however also possible that the base plate 4 is a component of this housing, for example a component of the lock housing of the motor vehicle door lock. In any case, the conductive track arrangement 1 together with the electric component carrier are then in the operational state and can, in the example case, be used to control the motor vehicle door lock or to query individual components. To this end, it is only necessary for the conductive track arrangement 1 to be electrically connected to a control device in the motor vehicle via for example a connected plug or socket.