DE102005035102A1 - Electrically conductive connection and method for producing such - Google Patents

Abstract

Electrically conductive connection of at least two connection partners (1, 1 *) each with at least one conductive layer (3, 3 *), which on one side with a base layer (4, 4 *) and on the opposite side with a cover layer (5, 5 *), whereby in the cover layers (5, 5 *) the connection partner (1, 1 *) in the area of the connection superimposed access openings (2, 2 *) are provided and the line layers (3, 3 *) within these access openings (2, 2 *) are electrically conductively connected, the areas of the base layers (4, 4 *) opposite the access openings (2, 2 *) being retained, and a method for producing such a connection.

Description

The The present invention relates to an electrically conductive connection and a method for producing a corresponding electrical Connection to it.

In Electronic modules for Control devices, especially for Transmission controls, - too referred to as EM - are Hybrid control devices, Sensors and at least one plug connection, a so-called gear plug, for the electrical connection of the electronic module to the vehicle wiring harness or a parent Control unit available. The electrical connection between the Hybrid control unit, the sensors and the gear plug is known punched grid or flexible printed circuit boards (flex foils or FPCs). flexible Printed circuit boards face with plastic fully encapsulated punched grids the advantage on that facing them through their isolation conductive deposits in the gearbox (for example, abrasion chips) are completely protected. Although they are designed with complete isolation, they show they have a high flexibility on. This compensates for positional tolerances two parts to be contacted possible.

These Electronic modules are partly under a so-called ATF (Automatic Transmission fluid) installed in the gearbox and are the occurring there huge Temperature fluctuations (-40 ° C to + 150 ° C) exposed.

There are several embodiments of contacts between a flexible printed circuit board and functional assemblies (for example, sensors, connectors) known within an EM. For example, describes DE 10036900 C2 a Kontaktierverfahren in which a contact partner (for example, a punched grid of a sensor) is brought to a one side stripped PCB and brought to bear. The opposite side of the film is irradiated with laser light, whereby a welded joint is formed between the copper layer of the film and the contact partner.

DE 19715128 and DE 10157113 describe pressure or press-fit contacts for connecting a (flexible) conductor carrier to a contact partner or between two flexible conductor carriers.

DE 10224266 shows a bonding technique between a flexible and a rigid printed circuit board, which is carried out by means of a soldering.

ADVANTAGES OF INVENTION

The according to the invention electrically conductive connection is distinguished by the fact that the connection partners have only one access opening in the area of the connection which are opposite each other, the outer insulation the connection point remains and no additional isolation measures necessary. Another advantage is that the connection point due to the remaining outer insulation a high stability having.

The inventive method for producing an electrically conductive connection between two connection partners takes the opposite by ultrasonic welding, whereby the connection partners must be prepared only to a small extent and a cost-effective Connection with a high robustness and flat contact point result.

Besides, they are as a connection partner cost-effective flexible circuit boards with each other, together with a metallic one Ladder, such as punched grids, or with flexible flat cables connectable, with even flat cables to each other in this way can be connected.

The need flexible printed circuit boards for connection only one-sided access through its cover sheet, wherein the base film over the entire surface remains isolated.

In an inventive electrically conductive connection of at least two connection partners, each having at least one conductor layer, which is provided on one side with a base layer and on the opposite side with a cover layer, are
provided in the cover layers of the connection partners in the region of the connection overlying access openings; and
electrically connect the conductor layers within these access openings,
wherein the areas of the base layers opposite the access openings are maintained.

In a further embodiment, in an electrically conductive connection of at least two connection partners with at least one conductor layer which is provided on one side with a base layer and on the opposite side with a cover layer, and a conductor element in the cover layer of the one connection partner in the Connection provided an access opening; and
the line layer is electrically conductively connected within these access openings to the conductor element,
wherein the region of the base layer opposite the access opening is maintained. Thus, the range of application of the compound according to the invention is advantageously extended to stamped grid and similar conductor elements.

In Preferred embodiment, the conductor layers are interconnected or flat with the conductor element in a contact area electrically connected. This flat connection (for example 2 × 1 mm) advantageously improves the mechanical stability of the joint compared to punctiform Connections such as resistance or laser welding.

The area Connection offers a further advantage over punctiform connections of the prior art, since their surface design has a higher current carrying capacity having.

In Another preferred embodiment is the access openings opposite each other lying region of the base layers substantially homogeneous and has only minor Penetrations or notches on. This offers the special Advantage that the junction has a high stability.

It it is preferred that the electrically conductive connection is a welded joint, in particular ultrasonic welding connection is. As a result, preparation times for the preparation of the compound reduced.

It is particularly advantageous that the connection partners as interconnects or conductive layers of flexible printed circuit boards with one-sided Access, of conductor elements of punched grids and / or ribbon cables are formed, since thus a wide range of applications is possible.

According to the invention, in the method for producing an electrically conductive connection between two connection partners, the following method steps are carried out:
(S1) arranging the connection partners with exposed sections to be connected in an opposite position;
(S2) compressing the sections to be joined until they lie against each other;
(S3) Welding the pressed-together sections by means of ultrasonic welding. It is advantageous that in the process step (S2) the compression takes place by means of a welding device.

In preferred embodiment, the welding device has two to each other pointing stamp-shaped Components with projections, which on opposite Front ends of the components are arranged and preferably like a pin are formed, wherein they are in the longitudinal direction have a cross section of an acute triangle. These Components are in step (S2) by applying a changeable force pressed together. By the variability this power is it possible connecting different strong contact partners.

in the Process step (S3) takes place establishing the electrical connection by applying changeable Ultrasonic vibrations. By also at the contact point the weld still existing all over Insulation has the contact / weld one opposite one Welding type the prior art better mechanical stability. At a resistance welding for example, would have the insulation of the base film can be removed in the welding area, what a more expensive foil (two-sided access) and a lower mechanical Strength in the welding area would result because in this area only the copper foil with a typical Strength from 35 ... 70 μm would be present.

To contact is made, the junction is largely isolated, because the isolation of the base films only in small point-like areas from the welding tools was penetrated. This results in an advantageous protection against short circuits or contact bridges through chips. A post-treatment for the preparation of an insulation of the joint is not required.

For the inventive ultrasonic welding of Connecting partners such as flexible printed circuit boards with each other, flexible Printed circuit board with conductor strips (punched grid) is no special pretreated surface on the to be welded Metals needed. This is not only cheaper, Special offers the advantage of giving up on others Connection techniques very common needed tinned surface (in particular with punched grids) a danger of short circuit due to so-called Zinnflitter avoids.

Of the Effort for the presentation of the contact partner at the interface is very low. In the case of a punched grid is sufficient a suitable punching on the interface in contrast to Laser welding in the prior art, in which a melting depth of the Contact partner of 0.5 to 1 mm is required, which helps to avoid of a complete Melting one extraordinarily massive and expensive design of the contact partner required.

The inventive method by ultrasonic welding stands opposite the laser welding process from the prior art as well characterized by that for the welding device a much smaller investment is necessary.

Further Advantages, details and features of the invention are themselves subsequent Description part and to see the drawings.

DRAWINGS

The Invention will be described below with reference to the figures in the drawing specified embodiment explained in more detail.

It shows:

1 two exemplary flexible circuit boards in a schematic representation in the manufacture of a contact according to the inventive method;

2 the connection after 1 after production; and

3 an exemplary connection of a flexible circuit board with a conductor element.

DESCRIPTION OF THE EMBODIMENT

In 1 are two exemplary flexible circuit boards 1 . 1* shown schematically in the preparation of a contact according to the inventive method.

A Such a connection point can, for example, in a transmission control be arranged of a vehicle.

The flexible circuit boards 1 . 1* are layered in a known manner, each with a conductor layer 3 . 3 * made of copper foil of a thickness of 35 or 70 microns is usually used. The conductor layer 3 . 3 * is on one side of a base layer 4 . 4 * and on the opposite side of a cover layer 5 . 5 * Mistake.

In the illustrated contacting example, the flexible circuit boards 1 . 1* with their cover layers 5 . 5 * arranged one above the other, wherein in the region in which a connection between the conductor layers 3 . 3 * is to be produced, the outer layers 5 . 5 * in each case a so-called access opening 2 . 2 * exhibit.

In this connection section are two stamp-shaped components 6 . 6 * opposite standing on the respective base layer 4 . 4 * the flexible circuit boards 1 . 1* applied and each acted upon by a force F. The force F causes the components 6 . 6 * and thus the areas of the flexible printed circuit boards to be connected 1 . 1* pressed on each other. This is possible because the base layers 4 . 4 * and the conductor layers 3 . 3 * have a certain flexibility and a small layer thickness.

The stamp-shaped components have on their opposite front surfaces thorn-like Vor jumps 7 . 7 * which have a cross section in their longitudinal direction, which forms an acute-angled triangle in this example. The tips of these projections 7 . 7 * each penetrate the base layers 4 . 4 * and are in mechanical contact with the side of the conductive layer 3 . 3 * that with the base layer 4 . 4 * connected is. About a variability of the force F, the penetration depth and the compression force of the line layer sections to be connected can be influenced. The pressed-on conductor layer sections form a contact surface 8th which extend in the longitudinal direction of the superposed conductor layers 3 . 3 * that is, extending in the drawing plane to the left and right and perpendicular to it from the plane of the drawing up and down.

The stamp-shaped components 6 . 6 * are part of an ultrasonic welding device, which is not shown for reasons of clarity, and are designed as so-called sonotrodes. These sonotrodes become after pressing the conductor layer sections and forming the contact surface 8th subjected to ultrasonic vibrations, which a swinging movement S in the direction of the longitudinal plane of the contact surface 8th To run. This oscillatory movement S of the sonotrodes is via the projections 7 . 7 * on the base layers 4 . 4 * and conductor layers 3 . 3 * mechanically transmitted. As a result, in a known manner, a welding of the contact partners in the contact surface 8th the sections of the conductor layers 3 . 3 * , which form a mechanical and electrical connection after welding.

A Modification of the force F and the oscillatory motion S during the welding leads to a advantageous influencing the welding result, which thus for different executed contact partners can be adjusted accordingly.

After the welding process, the oscillatory motion S is set. The sonotrodes are withdrawn, resulting in the 1 in the opposite direction of the force F takes place. 2 shows the welded joint with the contact surface 8th , In the connecting sections above and below the contact surface 8th remain notches 10 , the thorn-like projections 7 . 7 * of the components 6 . 6 * in the base layers 4 . 4 * , Due to the strength of the base layers 4 . * 4 and the geometry of the thorn-like projections 7 . 7 * are the notches 10 influenced. The notches 10 However, their size or size are so small that chips, originating from Getriebeabrieb or the like, no short circuits or contact bridges between different conductor layers 1 . 1* can produce in different places. The joint thus advantageously makes no additional insulation necessary. The mechanical strength of this joint is reinforced by the remaining base layer sections in the region of the joint. The notches 10 reduce this strength but only minimally.

3 shows an example of a connection point between a flexible printed circuit board 1 and a conductor element 9 which may for example be part of a stamped grid or a knife of a plug. The flexible circuit board 1 corresponds with their nature of those after 1 and is with her access opening 2 to the conductor element 9 arranged pointing away. It applies here already at above 1 described sequence of welding. Different here, however, is that only the component 6 with its thorn-like projections 7 the base layer 4 the flexible circuit board 1 penetrates, whereas the oppositely arranged component 6 * with its projections 7 * directly in contact with the contact partner to be connected.

The The invention is not limited to the embodiments explained above limited, but on diverse Modifiable manner.

So it is possible, for example, that the projections 7 * of the components 6 * are designed for different contact partners with different geometry shapes.

In the 1 and 3 The versions shown can also be transferred to the connection of two flexible flat cables (FFC). In this case, the cover layer is formed integrally with the base layer and encloses the respective conductor element or the conductor layer. In this case, the insulation is removed on one side of the FFC in the region of the joint. Then, the two FFCs are superimposed so that copper lies on top of copper. Also in this case, the insulations are first penetrated by the projections of the sonotrodes, before the welding of the two conductive layers takes place by means of ultrasound as described above.

LIST OF REFERENCE NUMBERS

Claims (14)

Electrically conductive connection of at least two connection partners ( 1 . 1* ) each having at least one conductive layer ( 3 . 3 * ) on one side with a base layer ( 4 . 4 * ) and on the opposite side with a cover layer ( 5 . 5 * ), wherein - in the outer layers ( 5 . 5 * ) of the connection partners ( 1 . 1* ) in the region of the connection of overlapping access openings ( 2 . 2 * ) are provided; and - the conductor layers ( 3 . 3 * ) within these access openings ( 2 . 2 * ) are electrically connected, wherein the access openings ( 2 . 2 * ) opposite regions of the base layers ( 4 . 4 * ) are maintained. Electrically conductive connection of at least two connection partners ( 1 . 9 ) with at least one conductive layer ( 3 ) on one side with a base layer ( 4 ) and on the opposite side with a cover layer ( 5 ), and a conductor element ( 9 ), wherein - in the top layer ( 5 ) of the one connection partner ( 1 ) in the region of the connection an access opening ( 2 ) is provided; and - the conductor layer ( 3 ) within these access openings ( 2 ) with the conductor element ( 9 ) is electrically connected, wherein the access opening ( 2 ) opposite region of the base layer ( 4 ) is maintained. Electrically conductive connection according to claim 1 or 2, characterized in that the conductor layers ( 3 . 3 * ) with each other or with the conductor element ( 9 ) flat in a contact surface ( 8th ) are electrically connected. Electrically conductive connection according to one of claims 1 to 3, characterized in that the access openings ( 2 . 2 * ) in each case opposite region of the base layers ( 4 . 4 * ) is substantially homogeneous and only minor penetrations or indentations ( 10 ) having. Electrically conductive connection according to one of claims 1 to 4, characterized in that the electrically conductive connection a welded joint is. Electrically conductive connection according to claim 5, characterized in that the electrically conductive connection is an ultrasonic welding connection is. Electrically conductive connection according to one of Claims 1 to 6, characterized in that the connection partners ( 1 . 1* ) as interconnects or conductor layers ( 3 . 3 * ) of flexible printed circuit boards with one-sided access, of conductor elements ( 9 ) are formed by stamped gratings and / or ribbon cables. Method for establishing an electrically conductive connection between two connection partners ( 1 . 1* . 9 ), with the following method steps: (S1) arranging the connection partners ( 1 . 1* . 9 ) with exposed portions to be joined in an opposed position; (S2) compressing the sections to be joined until they lie against each other; (S3) Welding the pressed-together sections with ultrasound. Method according to claim 8, characterized in that in method step (S2), the compression by means of a welding device he follows. A method according to claim 8 or 9, characterized in that the welding device two mutually facing punch-shaped components ( 6 . 6 * ), the projections ( 7 . 7 * ). Method according to claim 10, characterized in that the projections ( 7 . 7 * ) at opposite ends of the components ( 6 . 6 * ) are arranged and formed like a pin, wherein they have a cross-section of an acute-angled triangle in the longitudinal direction. Method according to one of claims 8 to 11, characterized that in step (S2) the compression with application of a changeable Force (F) takes place. Method according to one of claims 8 to 12, characterized in that method step (S3) the establishment of the electrical connection by applying changeable Ultrasonic vibrations take place. Method according to one of claims 10 to 13, characterized in that in the method step (S2) the components with their projections ( 7 . 7 * ) a base layer ( 4 . 4 * ) of a flexible printed circuit board ( 1 . 1* ) penetrate like a dome.