Pipe connection structure and method for its manufacture

Abstract

A conductor connection structure (1) comprising a plurality of electrical conductors (2) whose ends (21) are stripped, arranged parallel to each other in a bundle, and electrically connected to each other in a splice (24), wherein the splice (24) is insulated against the ingress of moisture and electrically by a covering (3), wherein the covering (3) is formed by a sheathing element (31) made of planar insulating material, which has a retaining area (32) through which the ends (21) of the conductors (2) are guided, and a sheathing area (34) connected to and surrounding the retaining area (32), which encloses the splice (24) and at whose outer edge (35) facing away from the retaining area (32) the sheathing (3) is closed, characterized in that the retaining area (32) and the sheathing area (34) are permanently and inseparably connected to each other.so that a separation of the enclosing area (34) from the holding area (32) would result in damage to the enclosing area (34) and the holding area (32).

Description

The invention relates to a conductor connection structure according to the preamble of claim 1 and a method for its manufacture. US 2019 / 044297 A1 discloses a wire joining method for joining a plurality of wires extending through a wire holder, wherein each wire comprises a conductor and a sheath covering the conductor, and wherein the wire holder is made of a water-impermeable material and is provided with a plurality of through-holes, wherein the inner diameter of some through-holes within the plurality of through-holes differs from the inner diameter of other through-holes within the plurality of through-holes, the method comprising: installing the plurality of wires in through-holes, which are at least some of the through-holes from the plurality of through-holes, such that the plurality of wires extend through the at least some through-holes and project to one side of the wire holder with a predetermined length; removing the sheath on a portion in a longitudinal direction of each of the wires.The process involves installing a dummy plug in one of the remaining through-holes of the multiple through-holes in the wire holder, connecting the conductors positioned on one side of the wire holder to each other, and sealing a portion of the wire holder and the conductors projecting to one side of the wire holder by installing a sealing element on the wire holder after the conductors have been connected. US 6,107,573 A also discloses a watertight construction in which a convergent core splice section is formed. US 5,641,943 A describes a device and method for joining the end sections of electrical conductors to prevent the formation of a breathing effect in the joined end sections of the electrical conductors. The object of the invention is to provide a conductor connection structure suitable for the automated connection of several electrical conductors, which electrically insulates the connection point and protects against the ingress of moisture, and to provide a manufacturing method for such a conductor connection structure. The object is achieved according to the invention, on the one hand, by a conductor connection structure comprising a plurality of electrical conductors, the ends of which are stripped, arranged parallel to each other in a bundle and electrically connected to each other in a splice, wherein the splice is insulated against the ingress of moisture and electrically by a covering, wherein the covering is formed by a covering element made of planar insulating material, which has a holding area through which the ends of the conductors are guided, and has a covering area permanently connected to the holding area, surrounding the holding area, which encloses the splice and at whose outer edge facing away from the holding area the covering is closed. A splice is understood to mean any permanent electrical connection of the conductor ends, which can be produced, for example, by soldering, crimping, ultrasonic welding or similar joining methods commonly used in the industry. On the other hand, the object of the invention is solved by a method for producing a conductor connection structure in which a plurality of electrical conductors are provided, their ends are stripped, arranged parallel to each other in a bundle and electrically connected to each other in a splice, and the splice is insulated against the ingress of moisture and electrically by a covering, wherein the ends of the conductors are guided through a holding area of ​​a covering element made of planar insulating material, and a covering area of ​​the covering element surrounding the holding area is positioned enclosing the splice and the covering is then closed. Advantageous embodiments of the invention are the subject of the dependent claims. In one embodiment of the proposed conductor connection structure, it may be provided that the holding area and the sheathing area are made in one piece from an insulating material, or that the holding area is made from a first insulating material and the sheathing area is made from a second insulating material, and that the holding area and sheathing area are permanently connected to each other. A permanent connection is understood to mean a connection that is inseparable in a manufacturing sense, i.e., a connection that cannot be broken without damaging the individual parts. For example, the casing element may have a holding area made of a first, in particular permanently elastic, insulating material, and this holding area may be permanently connected to a casing area, for example by gluing, fusing, or otherwise welding it, which consists of a second, in particular shrinkable, insulating material. A one-piece or at least permanently bonded design of the holding area and the covering area of ​​the casing element enables a simple, cost-effective design of an automatically manufactured pipe connection structure, thereby eliminating any potential leakage between the holding area and the covering area. In one embodiment of the proposed conduit connection structure, it may be provided that the casing element has a cup- or bell-shaped initial state, or that the casing element has a flat initial state. This corresponds to the procedural design in which a cup- or bell-shaped sheathing element is pushed or slipped over the splice, or a flat sheathing element is slipped over the splice. If the casing element has a flat initial state, it can be slipped over the splice and / or shaped and then sealed. For example, the casing area can be shrunk by applying heat to the splice to prevent wrinkling. Wrinkling can be reduced from the outset if the casing element has a cup- or bell-shaped initial state. In this case too, exposure to heat can further contribute to the sheathing element tightly enclosing the splice. A cup- or bell-shaped casing element can, for example, be manufactured in one piece from a sheet of insulating material, or the holding area and the casing area can be manufactured separately and then permanently joined together, for example by gluing, fusing, or otherwise welding. Advantageously, the holding area and the casing area can be made from two different sheet-like insulating materials. For example, with a cup- or bell-shaped sheath element, the conductors can first be guided from the side of the holding area through the holding area and then through the sheath area until the ends of the conductors protrude beyond the outer edge of the sheath area. The ends of the conductors can then be spliced ​​together, and subsequently the conductors can be pulled back so that the splice is located inside the sheath element and the sheath area encloses the splice. Alternatively, with a cup- or bell-shaped sheath element, the conductors can, for example, first be inserted into the sheath area at its outer edge and then guided through the holding area until the conductor ends protrude from the holding area. The conductor ends can then be spliced ​​together, and the bell- or cup-shaped sheath element can be turned inside out so that the inside of the sheath area becomes the outside, thus enclosing the splice. In one embodiment of the proposed conduit connection structure, it may be provided that the casing is closed by permanently connecting the outer edge of the casing element to itself, or that the casing is closed by permanently connecting the outer edge of the casing element to a closure element. This corresponds to a procedural design in which the covering is closed by permanently connecting the outer edge of the covering element to itself, in particular by welding, gluing or crimping, or the covering is closed by permanently connecting the outer edge of the covering element to a closure element, in particular by welding, gluing or crimping. In other words, either the outer edge of the sheathing element itself forms the closure of the sheathing, or the sheathing element is connected to an additional closure element, which in this way becomes part of the sheathing of the splice and the ends of the conductors connected within it. In particular, designs where the sheath is sealed by permanently bonding the outer edge of the sheath element to itself offer a very simple and cost-effective way to automatically produce a splice in which multiple conductors are electrically connected. For certain applications, however, it may be advantageous to seal the sheath element with an additional closure element to create the sheath. In one embodiment of the proposed conductor connection structure, it may be provided that the sheathing is filled with a curable filler material, and / or that the sheathing is shrunk onto the splice or onto the filler material. This corresponds to the procedural design in which the covering is filled with a curable filler material, in particular epoxy resin, acrylic resin or silicone, and / or the covering is heated and thereby shrunk onto the splice or onto the filler material. Filling the sheath with a curable filler material improves the resistance of the cable connection structure to external influences, such as mechanical, chemical, or thermal stresses. At the same time, the filler material forms a smoother structure than the splice, to which a shrunk-on sheath section of the sheathing element can adhere to form a tight seal. In one embodiment of the proposed cable connection structure, it may be provided that the holding area in the initial state has receiving openings for the cables, or that the ends of the cables are pierced through the holding area. This corresponds to the procedural design in which the ends of the cables are guided through receiving openings provided for this purpose in the holding area, or the ends of the cables are pierced through the holding area. Designs with pre-formed openings for the cables offer the advantage that the relative positions of the individual cables are defined and that the sealing of the retaining area against the cables can be influenced by the design. If there are more openings than cables to be connected, the excess openings can be closed, for example, with blanking plugs, adhesive, a curing filler, or similar materials. It is also possible to close excess openings by melting and / or shrinking the material from which the retaining area is formed. This avoids the need for additional materials such as adhesives or fillers. Designs in which the ends of the cables are pierced through the retaining area are particularly cost-effective to manufacture. Furthermore, with a suitable choice of material for the retaining area of ​​the casing element, or, in the case of a one-piece design, for the entire casing element, these designs are self-sealing. For example, a permanently elastic material that has been pierced by a cable—i.e., where no material has been removed to create an opening for the cable—exerts a radial force acting in all directions on the cable protruding through the retaining element because the permanently elastic material is displaced by the cable, thus generating a reaction force. In one embodiment of the proposed conductor connection structure, the conductor ends may be provided with an insertion aid, in particular a needle, a point, a ferrule, a crimp, or an insulating section. It is also possible for the conductor ends (21) to themselves be designed as an insertion aid, in particular by at least partially welding or soldering the ends (21). This can, for example, eliminate the need for separate ferrules as insertion aids, thereby reducing assembly effort. In general, a insertion aid mounted separately on the conductor ends can be replaced by any modification of the conductor ends that makes them sufficiently pointed and / or rigid to allow the conductors to pass through the retaining area. This corresponds to the procedural design in that the ends of the cables are provided with an insertion aid, in particular with a needle, a tip, a ferrule, a crimp or an insulating section, or that the ends of the cables themselves are formed as an insertion aid by at least partial welding or soldering. Attaching insertion aids to the ends of the cables facilitates the automated production of the cable connection structure. This is particularly useful in designs where the cable ends are pushed through the holding area, but can also simplify assembly even when the holding area has pre-made openings for the cables. Exemplary embodiments of the invention are explained in more detail below with reference to drawings. Figure 1 schematically shows a starting point of the process, Figure 2 schematically shows a first step of the process, Figure 3 schematically shows the end of the first step, Figure 4 schematically shows a second step of the process, Figure 5 schematically shows a third step of the process, and Figure 6 schematically shows a fourth step and the final result of the process. Corresponding parts are marked with the same reference symbols in all figures. Figure 1 shows a casing element 31 in the shape of a cup, i.e., a hollow cylinder open at one end, made of a planar insulating material. The bottom of the cup is formed by a retaining area 32 with a plurality of receiving openings 33. In the exemplary embodiment, the retaining area 32 is circular. Adjoining the retaining area 32 is a casing area 34, which is permanently connected to and surrounds the retaining area 32. In the exemplary embodiment, the casing element 31 is made in one piece from an insulating material; that is, the retaining area 32 and the casing area 34 consist of the same material and are inseparably connected to each other. The outer edge 35 of the casing area 34 is free; that is, it forms the rim of the cup. Below the sheathing element 31 are shown lines 2, each having a conductor 22 encased in insulation 23, namely (from left to right): firstly, individual lines 2; secondly, lines 2 bundled together such that the lines 2 are aligned parallel to each other and their ends 21 are touching; and thirdly, lines 2 whose ends 21 are electrically connected to each other in a splice 24. The provision of the lines 2 to be connected and the sheathing element 31 constitute the starting point of the process. Fig. 2 shows how the conductors 2 are guided through the receiving openings 33 of the retaining area 32 of the casing element 31, with their respective ends 21 leading. The result is shown in Fig. 3. Each conductor 2 is inserted into a receiving opening 33 of the retaining area 32. The ends 21 of the conductors 2 extend through the casing area 34 of the casing element 31 so far that they protrude beyond the outer edge 35 of the casing area 34. Fig. 4 shows how the ends 21 of the conductors 2 are joined together by ultrasound to form a splice 24, through which the conductors 22 are electrically connected. Subsequently, as shown in Fig. 5, the conductors 2, and thus also the splice 24 arranged at the ends 21 of the conductors 2, are retracted, as indicated by the arrow in Fig. 5, so that the splice 24 is moved into the interior of the sheathing element 31 formed by the sheathing area 34. Subsequently, the sheathing element 31, as shown in Fig. 6, is filled with a curable filler material 4 and then heated, causing it to shrink onto the splice 24 or onto the filler material 4 surrounding the splice 24. The outer edge 35 of the sheathing area 34 of the sheathing element 31 is bonded together by the filler material 4 to form a flap 36. The sheathing 3 is thus completed. Reference symbol list 1 Cable connection structure 2 Cable 21 End 22 Conductor 23 Insulation 24 Splice 3 Sheath 31 Sheath element 32 Retaining area 33 Receiving opening 34 Sheath area 35 Outer edge 36 Tip 4 Filler material

Claims

A conductor connection structure (1) comprising a plurality of electrical conductors (2) whose ends (21) are stripped, arranged parallel to each other in a bundle, and electrically connected to each other in a splice (24), wherein the splice (24) is insulated against the ingress of moisture and electrically by a covering (3), wherein the covering (3) is formed by a sheathing element (31) made of planar insulating material, which has a retaining area (32) through which the ends (21) of the conductors (2) are guided, and a sheathing area (34) connected to and surrounding the retaining area (32), which encloses the splice (24) and at whose outer edge (35) facing away from the retaining area (32) the sheathing (3) is closed, characterized in that the retaining area (32) and the sheathing area (34) are permanently and inseparably connected to each other.so that a separation of the enclosing area (34) from the holding area (32) would result in damage to the enclosing area (34) and the holding area (32). Conductor connection structure (1) according to claim 1 , characterized in that the holding area (32) and the covering area (34) are made in one piece from an insulating material, or the holding area (32) is made from a first insulating material and the covering area (34) is made from a second insulating material. Conduit connection structure (1) according to claim 1 or 2, characterized in that the casing element (31) has a cup- or bell-shaped initial state, or the casing element (31) has a flat initial state. Conductor connection structure (1) according to one of claims 1 to 3, characterized in that - the covering (3) is closed by the outer edge (35) of the covering area (34) of the covering element (31) being permanently connected to itself, in particular in the form of a lobe (36), or - the covering (3) is closed by the outer edge (35) of the covering area (34) of the covering element (31) being permanently connected to a closure element. Conductor connection structure (1) according to one of claims 1 to 4, characterized in that the covering (3) is filled with a curable filler material (4), in particular epoxy resin, acrylic resin or silicone, and / or the covering (3) is shrunk onto the splice (24) or onto the filler material (4). Cable connection structure (1) according to one of claims 1 to 5, characterized in that - the holding area (32) has receiving openings (33) for the cables (2) in the initial state, or - the ends (21) of the cables (2) are pierced through the holding area (32). Conductor connection structure (1) according to one of claims 1 to 6, characterized in that - the ends (21) of the conductors (2) have an insertion aid, in particular a needle, a tip, a ferrule, a crimp or an insulating section, and / or - the ends (21) of the conductors (2) themselves are formed as an insertion aid, in particular by at least partial welding or soldering of the ends (21). A method for producing a conductor connection structure (1) in which a plurality of electrical conductors (2) are provided, their ends (21) are stripped, arranged parallel to one another in a bundle, and electrically connected to one another in a splice (24), and the splice (24) is insulated against the ingress of moisture and electrically by a covering (3), wherein: - the ends (21) of the conductors (2) are guided through a holding area (32) of a covering element (31) made of planar insulating material, and - a covering area (34) of the covering element (31) surrounding the holding area (32) is positioned enclosing the splice (24), and subsequently the covering (3) is closed, characterized in that the holding area (32) and the covering area (34) are permanently and inseparably connected to one another, such that a separation of the covering area (34) from the holding area (32) causes damage to the covering area (34) and the holding area. (32) would result. Method according to claim 8, characterized in that a cup- or bell-shaped sheath element (31) is pushed or slipped over the splice (24), or a flat sheath element (31) is slipped over the splice (24). Method according to claim 8 or 9, characterized in that - the covering (3) is closed by permanently connecting the outer edge (35) of the covering element (31) to itself, in particular by welding, gluing or crimping, or - the covering (3) is closed by permanently connecting the outer edge (35) of the covering element (31) to a closure element, in particular by welding, gluing or crimping. Method according to one of claims 8 to 10, characterized in that the shell element (31) is filled with a curable filler material (4), in particular epoxy resin, acrylic resin or silicone, and / or the shell element (31) is heated and thereby shrunk onto the splice (24) or onto the filler material (4). Method according to one of claims 8 to 11, characterized in that the ends (21) of the conductors (2) are guided through receiving openings (33) provided for this purpose in the holding area (32), or the ends (21) of the conductors (2) are pierced through the holding area (32). Method according to one of claims 8 to 12, characterized in that the ends (21) of the conductors (2) are provided with an insertion aid, in particular with a needle, a tip, a ferrule, a crimp or an insulating section, and / or the ends (21) of the conductors (2) themselves are formed as an insertion aid, in particular by at least partially welding or soldering the ends (21).

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