WO2018224224A1

WO2018224224A1 - Braided conductor, method for producing same, and layered composite having such a braided conductor

Info

Publication number: WO2018224224A1
Application number: PCT/EP2018/061639
Authority: WO
Inventors: Georg BRENNER; Thomas Damerow
Original assignee: Leoni Kabel Gmbh
Priority date: 2017-06-09
Filing date: 2018-05-07
Publication date: 2018-12-13
Also published as: DE102017209777A1

Abstract

The invention relates to a method for producing a layered composite, wherein at least two layers are joined to form a layered composite, wherein a braided conductor is arranged between the two layers and wherein the braided conductor is produced by first flattening a plurality of wires and then braiding said wires together. The invention further relates to a corresponding layered composite and to a corresponding braided conductor.

Description

description

Wicker conductor, method for its production and layer composite with such a wicker conductor

The invention relates to a braid conductor, a method for its production and a composite layer with such a braid conductor.

Electrical conductors are sometimes inserted into a laminate, often referred to as a laminate, in order to realize additional functionality. For example, a conductor is inserted as a heating wire in order to realize a heating function. A layer composite has several layers, which are connected to one another in a planar manner. Such a layer composite finds use, for example, as a floor, wall cladding or generally as a cladding, e.g. in a vehicle as interior lining in the form of panels.

When inserting an electrical conductor between two layers there is regularly the requirement to make the conductor as thin as possible, because a too strong build-up leads regularly to an unwanted curvature of the surrounding layers. In contrast, due to the usually planar design and use of the layer composite, this layer composite should appear as uniform as possible. A structure housed in it should emerge as invisible as possible to the outside.

Against this background, it is an object of the invention to provide a conductor which is as small as possible and which should be usable in particular as a heating conductor in a layer composite. Furthermore, a method for producing such a conductor is to be specified as well as a layer composite with a corresponding conductor. The object is achieved by a braid with the features of claim 1, by a method with the features of claim 8 and by a layer composite with the features of claim 9. Advantageous embodiments, developments and variants are the subject of the dependent claims. In this case, the statements in connection with the braid conductor apply mutatis mutandis to the composite layer as well as for the process and vice versa.

The braid conductor serves in particular as a heating conductor for a composite layer, i. the braid conductor is designed in particular as a heat conductor. The braid conductor is made by braiding several flat wires into a strand like a plait. In other words, the braid conductor consists of several flat wires, which are braided into a strand like a plait. The wicker conductor is thus characterized by a special manufacturing process. Instead of first having several individual wires, i. Single wires to intertwine and then flatten the entire wire composite, e.g. To roll, a reverse order is chosen. The braid conductor is thus produced by first several in particular massive individual wires are first flattened and then intertwined braid-like. So it is first produced flattened individual wires. Flattening is generally understood to mean, in particular, forming by flattening, whereby the flat conductor is wider in a first direction when viewed in cross-section than in a second, different direction flattened single wire, ie a respective flat wire is monolithic, ie

formed in one piece and just not composed of several individual wires. The braid conductor is thus produced as a strand of several flat wires. It is essential in particular that the already flattened wires are intertwined, ie the braiding of the braided conductor takes place after the flattening of the wires. This results in a braid-like structure, ie a braid structure. This pigtail-like structure is not a hose at the moment, So does not include a cavity, but is a single strand or braid and is also referred to as braid.

By "intertwined" is meant, in particular, that at least and in particular exactly two groups of individual wires are formed, which have an intersecting course and in particular are guided alternately over and under one another Two adjacent individual wires of a first group extend in particular opposite to one another above and below the individual wires of a second group which crosses the first group.

The braid conductor thus produced is preferably characterized in that the cross-sectional area of the individual flat wires is identical, i. that the flat wires have identical Querschnittsgeomet s. The terms

Cross-sectional area, cross-sectional geometry and cross-section are used in particular synonymously. In a pressed braid conductor, in which initially round wires are intertwined with each other, they typically have different cross-sectional shapes, depending on the position in the braid, due to the pressing force applied during pressing from the outside. In particular, even a single flat wire has a constant, i.e. unchanged cross-section on.

The invention is based in particular on the idea that a flat conductor is used for a design of a conductor which is as flat as possible, ie a flattened conductor. Such a flat conductor can be inserted into a layer composite in such a way that the flat conductor in the layering direction is particularly thin, but comparatively wide parallel to the layers. In such flat conductors, however, there is the problem that they set up below a certain bending radius and therefore can be moved only limited in a curved course. The available area can then not optimally occupied by a ladder and accordingly not optimally used. Although the flat conductor is usually on the flat side, ie in a preferred orientation, usually well bendable, perpendicular to it, ie perpendicular to the preferential However, and over the width only very limited, so that the conductor during installation by itself sets up, that is rotated about 90 ° about the longitudinal axis, and bends over the width over the flat side. The application of a layer is made difficult or even impossible, in any case, the head is no longer flat.

In principle, it is possible to first intertwine several wires to form a braid conductor and subsequently to flatten, in particular to roll, the entire braid conductor. A braided conductor generally provides a large conductor cross-section, but such braid conductors are also fast. The invention is now based in particular on the observation that by interchanging the two production steps of braiding and flattening, a braid conductor is produced, which is significantly more flexible and thus can be laid with a particularly low bending radius, without setting itself up. Thus, instead of flat rolling a wire mesh to obtain a braid conductor, individual wires are first flattened, that is, in the present case. processed into flat wires, and then intertwined into a wire mesh, more precisely to a flat wire mesh, which then serves as a braid conductor.

Experiments have shown that braid conductors made in this way can be laid in significantly smaller beige radii without posing as braid conductors, which were first braided and then flattened. This is due in particular to the fact that, when jointly flattening, in particular by rolling a plurality of wires of a braid, the wires are compressed more strongly at the crossover points and therefore also more strongly deformed. As a result, the wires in the flattened braid are virtually interlocked with each other, which makes it difficult to move, in particular, scissors against one another. In contrast, individually flattened wires have along their length a uniform cross-section, so are not profiled and hooked accordingly not intertwined. The previously individually flattened strands are thus significantly more mobile in the mesh against each other, a corresponding braid is significantly more flexible in the plane across the width, without putting up. The special manufacturing process thus results in a particularly flexible Braid structure, which is characterized in particular by the fact that the flat wires interlock with each other particularly little. The flat wires each have a particularly smooth and uniform surface, which can not be achieved in this form by subsequent rolling of a braid.

Preferably, the individual wires are flattened by the individual wires are rolled. The flat wires are thus flattened by rollers and are thus each formed as rolled individual wires. The individual wires, which are assumed, are in particular round wires. Rolls or flat rolls represents a particularly simple and cost-effective method for the production of flat wires, in particular with a uniform surface.

The wires of the braid conductor are generally made of a conductive material, such as copper or aluminum. Particularly in one embodiment as a heating conductor appropriate materials are used with a certain and defined electrical resistance expedient to convert electrical energy in a certain amount of heat. Suitable examples are corresponding copper alloys. The individual wires are accordingly designed as resistance wires. A heating conductor differs in particular from a conventional conductor e.g. for data transmission due to higher electrical losses and correspondingly poorer transmission properties.

By flattening, a single wire has two flat sides and two side edges. In a suitable embodiment, the flat wire is thereby elliptically shaped in the cross-section or also lenticular, in particular when starting from a round single wire. The sides define a minimum height of the braid conductor after compression between two layers of a laminate and the two side edges corresponding to a width. Preferably, a respective flat conductor is wider by a factor of 2 to 10 than high, ie the width is greater by a factor of 2 to 10 than the height. The height is also referred to as thickness or thickness. A single flat wire preferably has a height in the range of 0.01 to 0.1 mm, more preferably 0.05 mm. A single wire then has, for example, a diameter of 0.1 mm before flattening and is flattened to a height of 0.05 mm. The width of a single flat wire is preferably between 0.3 and 0.4 mm.

The braid conductor preferably consists of 2 to 10 flat wires, particularly preferably 3 flat wires. A higher number of wires is basically possible and suitable. The braid conductor then correspondingly has a greater width and a height. In the layer composite, the height is measured perpendicular to the layers, the width parallel to it. For example, the width of a braided conductor of three wires in the layer composite is 0.7 mm. The height corresponds approximately to the height of a single wire. The flat wires are in particular all the same design, so they all have the same height and the same width.

Due to the improved buildability, the specially prepared braid conductor described above can be used profitably in a layer composite and is therefore expediently installed in such a layer composite. For this purpose, the braid conductor is arranged between two layers of the layer composite and the layers are then joined together, in particular adhesively bonded. In this case, the pommel-like structure of the braid conductor is flattened in particular. In particular, however, the force required for this purpose is advantageously significantly less than that force which is used for flattening an erected bend of a conventional flat wire or a subsequently flattened

Wicker conductor is needed.

By "layer composite" is meant in particular "laminate". The layer composite serves, for example, as floor, wall cladding, wallpaper or dashboard trim. Such composite layers are used, for example, in vehicles, even in aircraft. The two layers are in particular thin layers, ie in particular at most 1 mm thick. In such thin layers, the above-described erection of the conductor is in bending particularly critical, since the layers bulge or buckle particularly strong due to the small thickness.

The braid conductor is expediently designed as a heating conductor, so that the layer composite is equipped with a heating functionality. The layer composite can then be used for example as a heated floor. In particular, two terminals are provided, via which the network conductor can be connected to a power supply.

Preferably, the braid conductor is laid between the layers meandering. This is particularly advantageous in one embodiment as a heating element, i. when using the braided conductor as a heating conductor. A meandering shape is characterized in that the braided conductor is guided along its course between the layers in several curves. Usually this results in a pattern with a plurality of parallel longitudinal sections, which are connected to each other at the ends via curved pieces. The meander shape of the layer composite is traversed by the surface of the braid conductor so that sufficient heat is produced at each point. At the same time, the layer composite can be cut to any length without impairing the basic functionality of the braided conductor.

In a preferred embodiment, the braided conductor is laid with a bending radius which is less than five times the width. Preferably, this corresponds to a bending radius of 3mm.

Suitably, the braid conductor is laid with a bend radius of at least 1 mm and at most 3 mm between the layers. Such bending radii are significantly lower than those achievable with subsequently rolled braided conductors. Advantageously, however, larger bending radii than the minimum radius of 5 times the width described above. Particularly preferred is an embodiment with a Beigeradius of 10mm, which is particularly suitable for a laminate with heating functionality. The special braid conductor described here can easily be laid in appropriate bending radii, as stated above, without having to stand up. Laying before joining the layers is thus significantly simplified. The braid conductor is advantageously substantially stress-free between the two layers, since the layers do not have to work against the erection forces.

Another particular advantage of the special braided conductor is also obtained when joining the two layers, between which the braid conductor is arranged. Namely, the wires are advantageously automatically flat due to the flexible, braid-like mesh structure. flat between the layers. This results in particular from the fact that no tension due to a deployed braiding in curves or bends must be overcome. In a subsequently flattened braid conductor, the wires are all aligned along a common plane, and an area set up in a curve can only be depressed with a corresponding force. In contrast, the first flattened and subsequently braided wires of the braid conductor described herein are not necessarily aligned in a plane and therefore advantageously have no preferential orientation, i. no preferred direction. Rather, when the layers are compressed, the braid conductor automatically assumes a flat, i.e. level form. The force required for the assembly is thereby reduced correspondingly advantageous, as already indicated above. In a free, so not compressed between two layers braid conductor are the flat wires along the

Wicker conductor locally may be differently oriented and also the orientation of a single flat wire may change along the course. A particularly parallel alignment in a common plane is only realized when the braid conductor is compressed between two layers.

A layer composite which is produced according to the method described above, in addition to a simpler production still has the advantage that the layers which surround or surround the braid conductor are particularly stress-free. Furthermore, the composite layer is due to the particularly fla- Chen housing the braid conductor also very flat overall. The wicker ladder builds up very low and is therefore hardly or not at all recognizable from the outside. The surface of the laminate is particularly even. With regard to a functionality conveyed by the braid conductor, for example a heating functionality, the layer composite is likewise particularly uniform, since the special braid conductor can be laid with a particularly small bending radius and therefore particularly tight in the sense of being closely spaced. For example, the braid conductor is laid meandering as described above, wherein adjacent longitudinal sections are arranged at a distance of 20mm, so that therefore results in a Beigeradius of 10mm.

Embodiments of the invention will be explained in more detail with reference to a drawing. The sole FIGURE 1 shows schematically a layer composite with a braid conductor.

In Fig. 1, a layer composite 2 is shown in sections, which is used for example as a floor covering. The composite layer 2 has at least two layers 4, 6, between which a braid conductor 8 is arranged. In Fig. 1, the upper layer 6 is partially removed to show the underlying braid conductor 8. In the present embodiment, the braid conductor 8 serves as a heating conductor and consists of several, here three wires 10, i. Individual wires, which are made as resistance wires of a copper alloy. The braid conductor 8 is here meander-shaped, with longitudinal sections 12 which are parallel to each other and at a distance A of e.g. 20mm run. The course is indicated in Fig. 1 by a dashed line.

The braid conductor 8 is made by first flattening the wires 10 individually, rolling them in this case, and then intertwining them. For example, a single rolled wire 10, ie, a single flat wire, has a width of 0.3mm and a height of 0.05mm. Due to this special production, a particularly flexible braiding structure is produced, which can be arranged in a particularly low bending radius R without having to stand up. With the above-mentioned distance A, the bending radius B in the present case about 10mnn. Furthermore, the braid conductor 8 can also be arranged and compressed particularly easily between the layers 4, 6. As a result, the braid conductor 8 builds up particularly low and the composite layer 2 is particularly uniform when viewed from the outside.

Claims

claims

1 . Wicker conductor, in particular heating conductor for a composite layer, which is produced by braiding several flat wires into a strand in a braid-like manner.

2. wick according to claim 1, wherein the flat wires each having the same cross-sectional geometry.

3. wick according to claim 1 or 2, wherein the flat wires are each rolled individual wires.

4. wick according to one of claims 1 to 3, wherein a respective

Flat conductor is wider by a factor of 2 to 10 than high.

5. wick according to one of claims 1 to 4, wherein a respective

Flat wire height ranging from 0.01 to 0.1 mm.

6. wick according to one of claims 1 to 5, wherein the width of a single flat wire is between 0.3 and 0.4 mm.

7. wick according to one of claims 1 to 6, wherein this consists of 2 to 10 flat wires.

8. A method for producing a braided conductor, wherein a plurality of individual wires are first flattened in each case and are then intertwined braid-like.

9. Layer composite, with two layers, between which a braid conductor is arranged, which is made by braiding several flat wires into a strand.

10. Laminate according to claim 9, wherein the braid conductor is formed as a heating conductor.

1 1. Laminate according to one of claims 9 to 10, wherein the

Wicker conductor is laid between the layers meandering.

12. Laminate according to one of claims 9 to 1 1, wherein the

Wicker conductor has a width and is laid with a bending radius which is less than a five times the width.

13. Laminate according to one of claims 9 to 12, wherein the

Braided conductor is laid with a bending radius of at least 1 mm and at most 3 mm between the layers.