DE19705934C2 - Method and device for introducing wire-shaped conductor wires into a substrate - Google Patents

Description

The invention relates to a method and a device for embedding of bare wires in a thremoplastic insulating support.

Devices of the type mentioned above are used for introducing conductors pieces, especially for inserting wires into thermoplastic Body or in bodies provided with thermoplastic layers used. These bodies can have any shape, you only need one for the insertion tool at right angles to the press-in have freely accessible direction. This can be flat bodies, for example chip card substrates and the like, as well as cylinders, Be cones, bodies with bevels and the like.

According to US Pat. No. 3,674,602, a device is known in which a heated t, U-shaped, open tool an insulated wire leads, the fork-like leg ends of the tool  Warm and raise the thermoplastic layer, at the same time the warmed wire slightly pressed into the thermoplastic layer and finally, the thermoplastic layer raised is at least of pressed against the wire on both sides. Through relative movement between heated tool and holder with the thermoplastic Any desired line pattern is created on the substrate. The Device includes one that acts perpendicular to the substrate surface Knife for cutting the wire after the generation of the Line pattern. The insertion of the insulated wire into the substrate can can be supported by ultrasonic excitation of the tool or can only ultrasonic energy is used.

A disadvantage of the device is that the wire is not smooth and flush in the substrate can be laid, but in "raised" furrows is held. Another disadvantage is that the wire press tool or U-shaped opening should always be directed towards the wire laying axis got to. This means that the wire press tool head and the wire guide always be turned in the direction of the specified laying pattern must, which results in a high expenditure on equipment. Another disadvantage is that at the beginning of the laying process the wire catch with another device or be contacted must and that a precise height control of the wire press tool is necessary, the tool should stand still or slow Do not press the relative movement too deep into the thermoplastic substrate. The introduction of wire-shaped electrical and / or optical conductors in a substrate is commonly referred to in the literature as wire writing or Called wire laying.  

The general difficulty in laying the wires is the Fix the starting point of the wire and immediately afterwards the wire continue laying according to the given pattern, because at the starting point is the thermoplastic layer also in a soft state.

FR 24 66 936 A1 therefore specifies a device which connects the wire to the Solder the starting point to an existing post. The disadvantage is that on Starting point there must be a post.

DE 36 24 627 specifies a method according to which the wire is a Adhesion promoter layer that is only worn during or immediately before laying gene is converted into an adhesive state by means of pulsed radiation and then immediately returns to the non-stick state. A disadvantage here is that the wire needs an adhesion promoter layer and that the wire must be heated by pulsed radiation.

Generally, the wire is passed through after the laying is complete wedge-shaped knives (US 3,674,602; US 4,619,397 and US 5,365,657), by electrical voltage (DE 30 35 071) or by a wedge-shaped Projection on the laying tool (US 4,415,115) separately. A disadvantage of The above arrangements and methods is that the separator only for cutting the wire at the end of the installation process can be used and the start of the laying process not support.

According to DE 43 25 334 A1 is a device for producing a coil winding from winding wire on a winding support with a one wire guide device, movable relative to the winding support Winding head known in which the wire at its kinks under pressure  and temperature effects melted into the substrate surface becomes. The melting takes place by means of so-called thermal compresses ion or ultrasound.

A disadvantage of this method is that the wire is only in parts in the substrate is introduced. Another disadvantage is that in particular Press in using ultrasound-resistant substrate holders are necessary, which control the introduction of energy during pressing enable only with considerable effort. Another disadvantage is that the thermal energy on the piece of wire to be laid cannot be controlled.

Finally, according to DE 44 10 732, a method for producing a Chip card and a chip card known in which the manufacture of the coil by laying the wire on the substrate as well as connecting the Coil wire ends with the pads of a chip on the substrate respectively. A disadvantage of the method is that the wire laying method and Establishing a connection with the chip takes place directly with one another. Another disadvantage is that the relocation point and the termination of the Are linked to the chip connection.

According to DE-AS 11 83 151, it is known to bare wire attach thermoplastic plastic pads, taking the wire warmed at least in places and the warmed wire immediately into the Plastic pad is pressed in. For this purpose, a device used, which contains two electrodes, one electrode from one as Pipe trained power supply electrode and a stamp is made.  

DE 23 26 861 C2 describes a method for producing a circuit Micro modules described, in which contact pieces for the connections of the Micro modules attached to a substrate and the contact pieces over Connection circuits made of insulated wires attached to the substrate be connected to each other. The connecting wire is on a insulating support pad applied. A feed head is used for this a capillary tube through which the (insulated) wire to be applied is guided and which is heated with a heating coil.

Furthermore, DE 36 24 632 C2 describes a device for applying a Conductor network known in multiwire technology, in which a wire with a Installation head is fed and the bare wire after stripping Contacting surfaces is attached, the stripping by heating with a pulsed laser beam source.

All known methods have the disadvantage that the starting point cannot be fixed exactly when laying an endless wire and that the separators only for cutting the wire on Completion of the laying process can be used and the start do not support the laying process.

The invention has for its object a method and a Vorrich device for introducing electrical conductor pieces into a substrate ben, with the continuous pressing of the conductor piece into the substrate is made possible with little effort and high accuracy and in which both the start of the introduction and the completion of the introduction with high productivity and low technical effort is possible.

According to the invention this object is achieved with the features of Claims 1 and 7.

Advantageous embodiments of the method and the device are shown in specified in the subclaims.

In the method according to the invention, at least the has a thermoplastic layer, by means of a wire-shaped conductor piece of a press-in tool, a press-in foot in the lower area has introduced. The respective ladder section is under the press-in foot heated to a temperature during conductor insertion, which is above the softening temperature of the thermoplastic layer and the Press-in foot at the same time relative to the substrate according to a predetermined Pattern shifted. The conductor piece under the presser foot is in the Areas of the substrate where it is not inserted into the thermoplastic layer should be pressed to temperatures below the softening temperature the thermoplastic layer and held out on the presser foot exerted force with increasing wire diameter and with increasing displacement speed of the press tool foot increased.

It is advantageous for the insertion tool and the insertion foot to be rotationally symmetrical Metric design and reduction is required when the conductor section temperature increases ratu and to be provided with an axial bore. This results in the Possibility of the wire-shaped conductor section through the central axis of the Feeding tool and the conductor piece in any  Laying or indenting directions under the presser foot without the Need to turn the presser foot in the direction of movement.

It is also advantageous to use the press tool made of hard metal or extremely strong, thermally conductive ceramic, e.g. B. high-purity aluminum xid ceramics. So that is a good heat conduction from that Given the tool to the wire-shaped conductor piece and the tool also has a long service life.

It is also advantageous to heat the indentation tool and the indentation tool to heat up the conductor section under the press-in foot. In particular when using indirect electrical heating of the The tool temperature can be changed with simple means and thus depending on the material of the thermoplastic layer, Dimension and material of the wire-shaped conductor piece, pressure and Relative speed of the press tool to the substrate Pushing the conductor piece into a predetermined pattern on the Control the temperature of the conductor section under the tool base be recognized.

To increase the cooling speed of the tool base and for immediate setting of a conductor section temperature below the exp point of the thermoplastic at the locations of the substrate which the conductor piece is not pressed into the thermoplastic layer should be, e.g. B. at the end point of the line pattern, it is advantageous Tool foot by compressed gas flows, e.g. B. air or nitrogen flows Extract heat and so the conductor piece under and next to the Cool the tool base.  

Furthermore, it is advantageous to design the base so that the pressure area of the wire is as small as possible and that the inner radius of the Tool foot is designed depending on the wire diameter so that the conductor piece is pulled out of the tool horizontally abuts the inner radius.

This ensures that the conductor piece opens up very quickly is heated and on the other hand releases little energy to the substrate.

It is also advantageous to close the foot surface including the inner radius polish in order to exert only slight tensile forces on the conductor section.

Furthermore, it can be advantageous when using an electrically conductive Ceramic as a tool base to heat it directly electrically.

There is another design option for tool heating therein, the tool by short-wave electromagnetic radiation, for. B. to be heated by laser radiation. As a result, the heating or Cooling speed of the tool base compared to the indirect one Heating can be increased.

Furthermore, it is beneficial for achieving a high dynamic when heating up zen or cooling the respective conductor pieces to be laid through them Applying electrical voltage to heat up directly. It is for that advantageous to design the tool base as an electrode and over the Tool base to attach a counter electrode, the wire-shaped electrical conductor piece led from the counter electrode to the foot electrode and the area of the electrical conductor piece that is is located between the counter electrode and press-in foot, via the contact surface surface of the press-in foot and the counter electrode due to the with simple means controllable electrical voltage or controllable Electricity is heated.  

It is also possible, in addition to the press-in tool, in its axial direction tion acting clamping piece and also in its axial direction to arrange acting wedge-shaped cutting edge, so that the clamping piece between the press tool and the cutting edge tangential to it is arranged. Advantageously, the clamping piece and cutting edges piece each adjustable with respect to spring force on one another horizontal slide easily movable parallel to the substrate surface arranged, the carriage on the receiving device for the holding tion of the press tool is attached.

Furthermore, it was possible to pull the horizontal slide out with the there clamping piece and cutting piece in the direction of the press-in tool back into the starting position by means of a return device to classify. This arrangement ensures that the starting point and the End point is defined when laying a conductor pattern, without additional funds and without the beginning or / and the end of the wire-capable conductor piece soldered through stuck, glued or fixed in some other way.

Advantageous embodiments of the method and the device are shown in specified in the subclaims.

The process is used to process silver-plated copper wires, both have good mechanical as well as good RF and contact properties, particularly suitable.

The method according to the invention and the device according to the invention are characterized by a number of advantages:  

The device according to the invention consists of a few, relatively light and easy to manufacture individual parts.

The starting position and the end piece position of the line pattern is without further Aids can be defined.

The electrical conductor can be pressed in continuously can also be interrupted in any sections The energy required to insert the conductor piece is very low and can easily and through the electrical power can be controlled with high accuracy. It can preferably be silver plated Copper wire are used, the ideal conductor properties and the same has excellent RF properties at the time and also has a contact animals with the active and passive electronic components in enables simple way.

Compared to the methods known in the prior art, in which Thermocompression or ultrasound devices have been used advantageous that no ultrasound-resistant suspension is required that elaborate facilities for ultrasound generation and corresponding There are no tools. The simple, dynamic control of the energy input when pressing in the conductor piece and avoiding acoustic waves in the substrate.

The invention is explained in more detail using two exemplary embodiments tert. In the accompanying drawings:  

Fig. 1 shows a section through an indirectly heated rotationally symmetrical indentation for the insertion of wire in a thermoplastic substrate,

Fig. 2 position a section through the arrangement according to the invention in starting,

Fig. 3 is a section through the inventive arrangement for the end of the starting phase,

Fig. 4 is a section through the arrangement according to the invention during wire insertion,

Fig. 5 shows a section through the arrangement according to the invention at the end of the conductor wire pattern to be inserted and

Fig. 6 shows a section through a rotationally symmetrical indentation tool with an insulating inner sleeve for inserting directly heated wire.

The exemplary embodiments describe the introduction of a metallic bare conductor piece, preferably a silver-plated copper wire.

In Fig. 1, the wire 2 is guided through the thread opening 8 of the press tool 3 under the press tool foot 4 . The Eindrückwerk zeugfuß 4 is heated by electric heating coils 6 indirectly via the softening temperature of the thermoplastic layer 1, and presses the wire 2 in the thermoplastic substrate layer 1 a. The tool base 4 has an inner radius 7 adapted to the diameter of the wire 2 , the transition from inner radius 7 to the thread opening 8 simultaneously being the narrowest point of the axial insertion tool bore, the waist 23 . The Druckgaszufüh tion 5 is directed to the tool base 4 . The compressed gas is switched on via solenoid valves, not shown here, if required.

A plurality of pressurized gas supply lines 5 can be arranged around the tool base 4 , which feed lines can be switched on separately if necessary. To support the cooling of the already pressed-in wire piece 2 , it must be cooled separately with compressed gas. The insertion tool 3 is fixedly connected to the holding device 11 , which in turn is connected to the holding device 13 via the vertically movable slide 12 . The vertical slide is loaded with a variable pressure force F 25. A wire wrench 14 is fastened to the holding device 11 above the insertion tool 3 , through which the wire 2 is guided in the direction of the waist 23 and the tool foot 4 .

On the underside of the receiving device 13 there is a horizontal slide 18 which is connected to a return device 19 , in the example a pneumatic cylinder, via a linkage. Under sides of the horizontal slide 18 directly a rectangular clamping piece next to the indentation 3 and 15 immediately adjacent a cutting portion 16 are separately arranged and spring-mounted. The width of the clamping piece 15 and the cutting piece 16 approximately coincide with the size of the diameter of the insertion tool 3 .

In the starting position shown in FIG. 2, the unheated clamping piece 15 clamps the end of the wire 2 against the surface of the substrate 1 . At the same time, the cutting edge of the cutting piece 16 is pressed into the locking point 17 in the thermoplastic layer 1 . The wire 2 is heated below the insertion tool foot 4 by the clamping piece 15 above the softening temperature of the thermoplastic layer 1 and pressed into the thermoplastic layer.

At the same time, as shown in FIG. 3, the receiving device 13 moves in the opposite direction to the extension direction of the horizontal slide 18 . With the receiving device 13, the pressing tool 3 is pulled over the thermoplastic substrate layer 1, the wire 2 is thereby continuously withdrawn from the indentation 3 and pressed by the tool foot 4 in the thermoplastic layer 1 continuously to the variable pressure force F 25th The horizontal slide 18 remains because of the Fixie tion of the cutting piece 16 at the locking point 17 , the clamping piece 15 continues to clamp the beginning of the wire 2 .

To overcome the friction of the return device 19 and the horizontal slide 18 drawn in , the pneumatic cylinder of the return device 19 can be pressurized so that the sliding out of the horizontal slide 20 is supported.

Fig. 4 shows the end of the start phase. After a certain length of wire, which in Example 10.. , .15 mm, is securely inserted into the thermoplastic layer 1 and sufficiently anchored in it, the device 13 lifts; 21 so far from the substrate 1 that the clamping piece 15 and the cutting piece 16 about 1.. .13 mm above the substrate surface 1 , but the press-in tool foot 4 continues to press the wire 2 into the substrate 1 . The receiving device 13 ; 21 can now use the tool 4 to place or press any wire pattern on or into the substrate 2 . Here or shortly before the end of the wire insertion, the horizontal slide 20 which is pulled out is moved back into the retracted position 18 by the pneumatic return device 19 .

In FIG. 5, the arrangement according to the invention is shown during the final phase.

Shortly before the wire pattern lay in the substrate 1 , the output of the heater 6 was reduced and the cooling gas flow 5 directed onto the tool foot 4 was switched on. The wire 2 no longer reaches the temperature required to soften and sink the substrate layer 1 . The receiving device 13 is lowered. The cutting piece 16 notches the wire 2 , the clamping piece 15 presses the wire 2 against the substrate 1 . At the same time, the wire cutters 14 close. This ensures that the wire 2 is cleanly separated and at the same time formed a wire end of defined position and length for the impression or laying of a further wire pattern and is held in a constant position to the insertion tool 3 by the wire cutters 14 . After lifting the receiving device 13 and moving and lowering at the next starting point, the next wire pattern can be pressed into the substrate layer 1 .

Fig. 6 shows the insertion tool 3 and the counter electrode 10 for a case in which the wire 2 is heated by direct heating 24 of the wire 2 to a temperature above the softening temperature of the thermoplastic substrate layer 1 . The wire 2 is looped around a scheibenför shaped, easily rotatable, electrically conductive counterelectrode 10 and then passed through the thread opening 8 of a rotationally symmetrical insertion tool 3 under its tool base 4 . The outer tool base 4 is electrically conductive. Inside the insertion tool 3 is the inner sleeve 9 , which is designed as an electrically and thermally insulating layer. It is preferably made of wear-resistant ceramic. The stretched between the counter electrode 10 and the metallic tool base 4 section of the wire 2 forms the direct electric wire heater 24th This wire section is electrically heated to such an extent that it can be pressed into the substrate 1 . The electrical power can be measured and regulated using simple means.

An improvement of this method can still be achieved in that the insert tool 3 and the tool foot 4 ture already with indirect heating 6 to a temperature just below the softening of the substrate layer 1 is preheated and only the other, required for pressing in the substrate layer 1 increase in temperature by direct heating 24 of the wire 2 takes place.

Depending on the relative speed of the tool 3 with respect to the substrate 1 , z. B. with a wire diameter of 80 microns with versil bert copper wire 2, the pressing force. 1 .50 N. Furthermore, the pressure force 25 must be chosen the higher, the larger the foot surface 4 of the insertion tool 3 and the lower the insertion tool temperature.

REFERENCE SIGN LIST

1

Thermoplastic substrate layer

2nd

Ladder section; wire

3rd

Insertion tool

4

Insertion tool foot

5

Compressed gas supply

6

indirect electric heating

7

Inner radius of the press tool foot; waist

8th

Thread opening

9

Inner sleeve

10th

Counter electrode

11

bracket

12th

Vertical slide

13

Reception facility

14

Wire cutters

15

Clamp

16

Cutting piece

17th

Locking point

18th

Horizontal slide (retracted)

19th

Return device

20th

Horizontal slide extension

21

Pick-up device in working position

22

notched ladder section

23

waist

24th

direct electrical wire heating

25th

Pressing force F

Claims (14)

1. Method for embedding bare lead wires in a thermoplastic insulating support in the

• - At the beginning of laying the wire end is pressed by means of a clamping piece ( 15 ) against the insulating support surface and at the starting point of laying the wire ( 2 ) a cutting piece ( 16 ) at a locking point ( 17 ) in the insulating support surface ( 1 ) presses the insulation the carrier is then moved horizontally in the required direction and the cutting piece ( 16 ) and the clamping piece ( 15 ) remain in their ( 17 ) fixed position at the locking point,
• - After pressing a first length of wire into the insulating support, the wire being heated to a temperature which is above the softening temperature of the thermoplastic insulating support, the receiving device ( 13 ) is raised to such an extent that the pressing tool foot ( 4 ) the wire ( 2 ) can continue to press into the insulating support ( 1 ), but that the clamping piece ( 15 ) and the cutting piece ( 16 ) are no longer in engagement with the insulating support ( 1 ),
• - At least immediately before the end of the laying, the laying direction is chosen such that the wire ( 2 ) is below the cutting piece ( 16 ) and the clamping piece ( 15 ) and the wire ( 2 ) by lowering the laying temperature on the surface of the insulating support ( 1 ) is installed and
• - The wire ( 2 ) is notched by lowering the receiving device ( 13 ) with the cutting piece ( 16 ).

2. The method according to claim 1, characterized in that by the insertion tool foot ( 4 ) and the clamping piece ( 15 ) the beginning of the wire piece ( 2 ) to be subsequently installed and molded by means of wire pliers ( 14 ) until the laying again in the position of the insertion tool foot ( 4 ) is kept. 3. The method according to claim 1 or 2, characterized in that on the pressing tool foot ( 4 ) an adjustable between 0 and 100 N pressure force ( 25 ) acts, the pressure force ( 25 ) being proportional to the relative displacement speed and inversely proportional to the conductor piece temperature. 4. The method according to at least one of claims 1 to 3, characterized in that the insertion tool ( 3 ) and / or the piece of wire ( 2 ) to be inserted is heated by indirect electrical heating ( 6 ), and that the insertion tool foot ( 4 ) and / or the piece of wire ( 2 ) to be pressed in is rapidly cooled to temperatures below the softening temperature of the thermoplastic layer ( 1 ) by a compressed gas stream ( 5 ). 5. The method according to at least one of the preceding claims, characterized in that the insertion tool foot ( 4 ) and / or the wire piece ( 2 ) to be pressed in is heated directly by electromagnetic radiation. 6. The method according to at least one of the preceding claims, characterized in that the wire to be laid ( 2 ) between the insertion tool foot ( 4 ) and a counter electrode ( 10 ) is directly heated by passage of current. 7. Device for embedding bare lead wires in a thermoplastic insulating support consisting of

• - a base frame with a holding device for the insulating support,
• a moveable insertion tool ( 3 ) mounted on a carrier, which has a through opening ( 8 ) for the wire feed and is provided with a heating device ( 6 ; 24 ),

characterized in that a clamping piece (15) and a so korre spondierendes cutting piece (16) are arranged horizontally displaceably on a holding device (13), on a vertically höhenver adjustable holding device (13) via a vertical slide (12) has a holder (11) is arranged, on which the insertion tool ( 3 ) is det, the clamping piece ( 15 ) and the cutting piece ( 16 ) are each resiliently attached in the vertical direction. 8. The device according to claim 7, characterized in that a device is attached to the insertion tool ( 3 ) with which the insertion tool ( 3 ) with a vertically acting variable pressure raft F ( 25 ) is loaded. 9. The device according to claim 7 or 8, characterized in that in the vicinity of the press-in foot ( 4 ) at least one compressed gas supply ( 5 ) is arranged for cooling. 10. Device according to one of claims 7 to 9, characterized in that the through opening ( 8 ) in the form of an inner sleeve ( 9 ) is made of ceramic. 11. The device according to at least one of the preceding claims, characterized in that between the press-in foot ( 4 ) and a counter electrode arranged in the upper region of the device ( 10 ) an electrically insulating inner sleeve ( 9 ) is attached, the electrical conductor piece ( 2 ) from the Counter electrode ( 10 ) is guided to the press-in foot ( 4 ). 12. The device according to at least one of the preceding claims, characterized in that the insertion tool ( 3 ) and / or its insertion tool base ( 4 ) are rotationally symmetrical. 13. The device according to at least one of the preceding claims, characterized in that on the holder ( 11 ) above the insertion tool ( 3 ) a wire cutters ( 14 ) is attached. 14. The device according to at least one of the preceding claims, characterized in that a return device ( 19 ) is arranged on the receiving device ( 13 ), with which the horizontal slide ( 18 ) can be brought into its starting position.