Cable assembly with integral sealing element

Abstract

An assembly for an electrical system is provided. The electrical system assembly includes an electrical cable and a sealing element. The sealing element surrounds the electrical cable and is integral with the electrical cable. The sealing element is constructed from or otherwise includes a conductive polymer composite material.

Description

[Technical field]

[0001] This application claims the benefit of priority to U.S. Patent Application No. 17 / 176,090, filed February 15, 2021, which is incorporated by reference in its entirety.

[0002] Government Licensing Rights This invention was made with Government support under Contract No. FA8730-17-C-0010 awarded by the Department of Defense. The Government has certain rights in this invention.

[0003] FIELD OF THE DISCLOSURE This disclosure relates generally to electrical systems, and more particularly, to cable assemblies for electrical systems. [Background technology]

[0004] An electrical system, such as a controller, may include an internal compartment for housing an electrical circuit. When communicating with a device outside the internal compartment, a cable connected to the electrical circuit may be passed through a hole in a wall of the housing. However, environmental debris (e.g., dust) and / or unwanted signals (e.g., noise) may also pass through the hole. Such debris and noise may interfere with the proper operation of the electrical circuit. Therefore, it is known in the art to provide the housing with a separate gasket that engages the cable, especially when the housing is assembled to seal the hole. However, placement of such a gasket may be difficult when the wall is located inside the housing. It is also known to provide a sealed terminal (e.g., receptacle) in the wall, where a cable within the compartment is mated to one side of the terminal and a cable outside the compartment is mated to the other side of the terminal. However, such sealed terminals are often bulky and may not be suitable for electrical systems of compact size. Thus, there is a need in the art for an improved cable assembly. Summary of the Invention

[0005] According to one aspect of the present disclosure, an assembly for an electrical system is provided. The electrical system assembly includes an electrical cable and a sealing element. The sealing element surrounds and is integral with the electrical cable. The sealing element is constructed from or otherwise includes a conductive polymer composite material.

[0006] According to another aspect of the present disclosure, another assembly for an electrical system is provided. The electrical system assembly includes a housing and a cable assembly. The housing includes a first compartment, a second compartment, and a wall. The wall is between the first compartment and the second compartment to form the first compartment and the second compartment. The wall is configured with an opening. The cable assembly includes an electrical cable and a sealing element. The cable assembly is configured to prevent at least radio frequency signals from being transmitted through the opening. The electrical cable extends through the opening into the first compartment and the second compartment. The sealing element is disposed in the opening and adhered to the electrical cable.

[0007] According to another aspect of the present disclosure, a method of manufacture is provided, in which a sealing element is integrally formed with an electrical cable to provide a cable assembly. The cable assembly is disposed with a housing. The housing includes a wall and an opening extending through the wall. The electrical cable protrudes from the opening. The sealing element is disposed within the opening such that the cable assembly blocks the opening and is configured to at least prevent transmission of radio frequency signals through the opening.

[0008] The sealing element can include a first segment and a second segment, and forming the sealing element can include adhering the electrical cable to the first segment and the second segment, the electrical cable being between the first segment and the second segment.

[0009] The sealing element may be constructed from or may otherwise include a conductive polymer composite material.

[0010] The electrical cable may be configured as a flexible ribbon cable.

[0011] The electrical cable may include a sheath and electrical conductors within the sheath. The sealing element may be bonded directly to the sheath.

[0012] The conductive polymer composite can include a polymer foam and a plurality of metal particles embedded within the polymer foam.

[0013] The conductive polymer composite may be configured to block the transmission of radio frequency (RF) signals.

[0014] The sealing element may include a first segment and a second segment, and the electrical cable may be between the first segment and the second segment.

[0015] The sealing element may have a polygonal cross-sectional shape.

[0016] The electrical system assembly may include a conductive adhesive capable of adhering the sealing element to the electrical cable.

[0017] The electrical system assembly may include a housing. The housing may include a wall. The electrical cable may pass through an opening in the wall. The sealing element may be disposed within the opening. The sealing element may be configured to fill an annular gap between the electrical cable and the housing.

[0018] The wall may have a first side and a second side. The opening may extend through the wall between the first side and the second side. A first portion of the sealing element may protrude from the first side. Additionally or alternatively, a second portion of the sealing element may protrude from the second side.

[0019] The opening may be configured as or may otherwise include a dovetail slot in the wall.

[0020] The housing may also include a lid. The sealing element may be sandwiched between the wall and the lid.

[0021] The housing may be configured with a first compartment and a second compartment. A wall may be between the first compartment and the second compartment. A first end of the electrical cable may be in the first compartment. Additionally or alternatively, a second end of the electrical cable may be in the second compartment.

[0022] The sealing element may surround the electrical cable.

[0023] The sealing element may be constructed from or may otherwise include a conductive polymer composite material.

[0024] The sealing element can include a first segment and a second segment. The first segment and the second segment can be disposed within the opening. The electrical cable can be between the first segment and the second segment.

[0025] The present disclosure may include any one or more of the individual features disclosed above and / or below, either alone or in any combination thereof.

[0026] The features and operations of the present invention will become more apparent in light of the following description and the accompanying drawings. [Brief description of the drawings]

[0027] [Figure 1] FIG. 2 is a schematic diagram of an electrical system. [Diagram 2] FIG. 2 is a cross-sectional view of the housing of the electrical system in the xz plane. [Diagram 3] 3 is a cross-sectional view of the electrical system housing in the xy plane taken along line 3-3 of FIG. 2. [Figure 4] 4 is a cross-sectional view of the electrical system housing in the yz plane taken along line 4-4 of FIG. 2. [Diagram 5] FIG. 2 is a perspective view of the electrical system with the lid on the base of the electrical system housing removed. [Figure 6] FIG. 2 is a diagram of a cable assembly having hidden inner conductors shown diagrammatically in dashed lines. [Figure 7A] 7A is a cross-sectional view of an electrical cable for a cable assembly taken along line 7A-7A of FIG. 6. [Figure 7B] 7B is a cross-sectional view of another electrical cable for the cable assembly taken along line 7B-7B of FIG. 6. [Figure 8] FIG. 8 is a cross-sectional view of the cable assembly taken along line 8-8 of FIG. 6, where the electrical cable is shown without internal parts for ease of illustration. [Figure 9] FIG. 2 is a cross-sectional view of a portion of the seal element material. [Figure 10] FIG. 2 is a partial cross-sectional view of the electrical system in the yz plane. [Figure 11] FIG. 2 is a partial cross-sectional view of the electrical system in the xz plane. [Figure 12] The perimeter of the slot / opening and the perimeter of the sealing element are shown diagrammatically. [Figure 13] FIG. 2 is a partial cross-sectional view of the electrical system housing taken along the yz plane. [Figure 14] FIG. 2 is a cross-sectional view of the cable assembly. [Figure 15] FIG. 1 is a flow diagram of a method for manufacturing an electrical system. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] FIG. 1 illustrates an electrical system 20. The electrical system 20 may be configured as or include an electrical and / or electronic system. The electrical system 20 may be configured as, for example, a controller for an airborne, ground and / or waterborne vehicle or device. However, the present disclosure is not limited to such exemplary electrical system configurations. For example, the electrical system 20 may also or alternatively be configured as or include a communication system, a monitoring system, a junction box, and / or any other electrical system that may utilize one or more cable assemblies as disclosed herein.

[0029] 1 includes a first electrical component 22, a second electrical component 24, and one or more standalone cable assemblies 26A and 26B (collectively referred to as "26"). The electrical system 20 of FIG. 1 also includes an electrical system housing 28 for enclosing one or more of the electrical system components 22, 24, and 26.

[0030] 2, electrical system housing 28 is configured with one or more interior compartments 30A and 30B (collectively referred to as "30"), e.g., chambers, cavities, etc. Interior compartment 30 of FIG. 2 is collectively defined by a base 32 and a lid 34 of electrical system housing 28.

[0031] The housing base 32 of FIG. 2 includes a base wall 36 (e.g., a bottom wall), a perimeter wall 38 (e.g., an outer wall), and at least one interior wall 40 (e.g., an internal wall, bulkhead, divider, etc.). The base wall 36 may be a planar wall located at a first (e.g., bottom) end 42 of the electrical system housing 28. With reference to FIG. 3, the base wall 36 extends lengthwise (e.g., along the x-axis) between opposing first and second sides 44 and 46 of the electrical system housing 28. The base wall 36 extends widthwise (e.g., along the y-axis) between opposing third and fourth sides 48 and 50 of the electrical system housing 28.

[0032] The perimeter wall 38 is connected to the base wall 36. The perimeter wall 38 is located on (e.g., on, adjacent to, or proximate to) one or more of the housing sides 44, 46, 48, and 50. The perimeter wall 38 has a (e.g., rectangular) tubular configuration that provides a peripheral boundary of the electrical system housing 28 in the longitudinal and transverse (e.g., xy) planes. The perimeter wall 38 of FIG. 3 includes, for example, a number of perimeter wall segments 52-55. The first wall segment 52 is located on the first side 44 of the housing. The second wall segment 53 is located on the second side 46 of the housing. The third wall segment 54 is located on the third side 48 of the housing. The fourth wall segment 55 is located on the fourth side 50 of the housing. Each of the first and second wall segments 52, 53 in FIG. 3 extends widthwise (e.g., along the y-axis) between and connects to the third and fourth wall segments 54, 55. Each of the third and fourth wall segments 54, 55 in FIG. 3 extends lengthwise (e.g., along the x-axis) between and connects to the first and second wall segments 52, 53. With reference to FIG. 2, each of the wall segments 52-55 projects vertically (e.g., along the z-axis) from the base wall 36 to a distal end 58 of the perimeter wall 38, which may be proximate a second (e.g., top) end 60 of the electrical system housing 28.

[0033] The inner wall 40 is connected to the base wall 36. The inner wall 40 projects vertically (e.g., along the z-axis) from the base wall 36 to a distal end 62 of the inner wall 40, which may be flush with the peripheral wall distal end 58 (see also Figs. 3 and 4). The inner wall 40 has opposing faces 64 and 66, e.g., wall faces, and extends lengthwise (e.g., along the x-axis) therebetween. With reference to Fig. 3, the inner wall 40 extends widthwise (e.g., along the y-axis) between the third wall segment 54 and the fourth wall segment 55, and is connected to the third wall segment 54 and the fourth wall segment 55. See also Fig. 4.

[0034] The inner wall 40 of FIG. 3 includes one or more slots 68A and 68B (collectively referred to as "68"), e.g., channels, notches, etc. These slots 68 are disposed at respective discrete locations widthwise (e.g., along the y-axis) along the inner wall 40 between the third wall segment 54 and the fourth wall segment 55. Each of these slots 68 extends lengthwise (e.g., along the x-axis) through the inner wall 40 between the inner wall first surface 64 and the inner wall second surface 66. Each of the slots 68 extends widthwise (e.g., along the y-axis) within the inner wall 40 between respective opposing slot sides 70A, 70B (collectively referred to as "70") and 72A, 72B (collectively referred to as "72"). See also FIG. 4. 4, each of the slots 68 extends vertically (eg, along the z-axis) into the inner wall 40 from the inner wall distal end 62 to a respective slot end face 74A, 74B (collectively referred to as "74").

[0035] 2 and 4, the housing lid 34 is configured to surround the open end of the housing base 32 at the housing second end 60. The housing lid 34 of FIG. 2 and FIG. 4 is configured, for example, as a planar member that engages (e.g., vertically seals, contacts, etc.) with the housing base 32, more specifically, with one or more or all of the housing base parts 40 and 52-55. The housing lid 34 may be removably attached (e.g., mechanically secured) to the housing base 32. The housing lid 34 of FIG. 2 extends lengthwise (e.g., along the x-axis) between the housing first side 44 and the housing second side 46. The housing lid 34 of FIG. 4 extends widthwise (e.g., along the y-axis) between the housing third side 48 and the housing fourth side 50.

[0036] 3, the first compartment 30A extends lengthwise (e.g., along the x-axis) between and is defined by the first wall segment 52 and the interior wall 40 and its first surface 64. The first compartment 30A extends widthwise (e.g., along the y-axis) between and is defined by the third wall segment 54 and the fourth wall segment 55. With reference to FIG. 2, the first compartment 30A extends vertically (e.g., along the z-axis) between and is defined by the base wall 36 and the housing lid 34.

[0037] 3, the second compartment 30B extends lengthwise (e.g., along the x-axis) between and is formed by the second wall segment 53 and the interior wall 40 and its second surface 66. The second compartment 30B extends widthwise (e.g., along the y-axis) between and is formed by the third wall segment 54 and the fourth wall segment 55. With reference to FIG. 2, the second compartment 30B extends vertically (e.g., along the z-axis) between and is formed by the base wall 36 and the housing lid 34.

[0038] 4, the first slot 68A is surrounded by the housing lid 34. The housing lid 34 and the inner wall 40 may thereby collectively form a first opening 76A (e.g., a through hole) in the electrical system housing 28. As described below (see FIG. 5), the first opening 76A / first slot 68A fluidly couples the first compartment 30A and the second compartment 30B together before the first slot 68A receives the first cable assembly 26A. See also FIG. 3.

[0039] The second slot 68B is surrounded by the housing lid 34. The housing lid 34 and the inner wall 40 may thereby collectively form a second opening 76B (e.g., a through hole) in the electrical system housing 28. As described below (see FIG. 5), the second opening 76B / second slot 68B fluidly couples the first compartment 30A and the second compartment 30B together before the second slot 68B receives the second cable assembly 26B. See also FIG. 3.

[0040] Each of the electrical system housing 28 and its components 32 and 34 may be constructed from an electrically conductive material, such as, but not limited to, a metal. Examples of electrically conductive materials may include, but are not limited to, (e.g., corrosion resistant) metal alloys, such as aluminum (Al), copper (Cu), nickel (Ni), titanium (Ti), carbon (C), and alloys including one or more of the foregoing metals. The electrically conductive material may be coated with a protective coating, which may be selected to provide corrosion protection to the respective components (e.g., 28, 32, 34).

[0041] Referring to FIG. 5, the first electrical component 22 may be configured as or include an electronic circuit. The first electrical component 22 of FIG. 5 includes, for example, a printed circuit board (PCB) 78 and one or more circuit elements (e.g., 80A-H, collectively referred to as "80"), e.g., electronic components. These circuit elements 80 are mounted on the printed circuit board 78. Each of the circuit elements 80 is electrically coupled with one or more respective conductive paths (e.g., tracks) on the printed circuit board 78. Examples of the circuit elements 80 include, but are not limited to, processing device(s), memory device(s), resistor(s), capacitor(s), transistor(s), inductor(s), diode(s), switch(es), input device(s), output device(s), etc. Each circuit element 80A and 80B in FIG. 5 is specifically configured as a terminal 82A, 82B (collectively referred to as "82"), such as an input and / or output (I / O) device, for example, but not limited to, a receptacle.

[0042] The first electrical component 22 is disposed within the first compartment 30A. The first electrical component 22 is attached to the electrical system housing 28, and more specifically, to the base wall 36, for example.

[0043] The second electrical component 24 may be configured as or include an electronic circuit. The second electrical component 24 of FIG. 5 includes, for example, a printed circuit board (PCB) 84 and one or more circuit elements (e.g., 86A-F, collectively referred to as "86"), e.g., electronic components. These circuit elements 86 are mounted on the printed circuit board 84. Each of the circuit elements 86 is electrically coupled with one or more respective conductive paths (e.g., tracks) on the printed circuit board 84. Examples of the circuit elements 86 include, but are not limited to, processing device(s), memory device(s), resistor(s), capacitor(s), transistor(s), inductor(s), diode(s), switch(es), input device(s), output device(s), etc. Each circuit element 86 in FIG. 5 is specifically configured as a terminal 88A, 88B (collectively referred to as "88"), such as an input and / or output (I / O) device, for example, but not limited to, a receptacle.

[0044] The second electrical component 24 is disposed within the second compartment 30B. The second electrical component 24 is mounted to the electrical system housing 28, and more specifically, to the base wall 36, for example.

[0045] Each of the cable assemblies 26A, 26B includes an (e.g., flexible) electrical cable 90A, 90B (collectively referred to as "90") and sealing elements 92A, 92B (collectively referred to as "92"). Each of the cable assemblies 26 of FIG. 5 also includes one or more terminals 94A, 94B (collectively referred to as "94") and 96A, 96B (collectively referred to as "96"), such as, but not limited to, input and / or output (I / O) devices, such as plugs.

[0046] 6, an electrical cable 90 is adapted to transmit electricity and / or communicate signals. The electrical cable 90 may be, but is not limited to, a (e.g., flexible) ribbon cable, such as a (e.g., shielded) coaxial ribbon or a (e.g., shielded) flex cable. The electrical cable 90 of FIG. 6 has a length extending longitudinally along a longitudinal centerline 98 of each cable assembly 26 between opposing longitudinal ends 100 and 102 of the electrical cable 90.

[0047] The electrical cable 90 of Figure 6 includes a sheath 104 and one or more conductors 106 at least partially disposed within and / or covered by the sheath 104. The conductors 106 may be configured as conductive wires or conductive layers, e.g., thin films within a laminate. Each conductor 106 may be constructed from a conductive material, such as a metal, e.g., copper (Cu). The sheath 104 may be constructed from a dielectric / non-conductive material, such as a polymer.

[0048] 7A and 7B, the electrical cable 90 may also include a shielding material 108, such as, but not limited to, a woven or non-woven metal. The shielding material 108 is adapted to shield one or more conductors 106 from external interference. With reference to FIG. 7A, the shielding material 108 may be wrapped around each individual conductor 106. With reference to FIG. 7B, the shielding material 108 may alternatively (or additionally) be wrapped around a group of conductors 106. The shielding material 108 of FIGS. 7A and 7B may be embedded within or covered by the sheath 104.

[0049] 6, sealing element 92 is disposed longitudinally along a centerline 98 between a cable first end 100 and a cable second end 102, e.g., approximately midway between ends 100 and 102. Sealing element 92 is integrally configured with electrical cable 90. Sealing element 92 may, for example, be bonded (e.g., attached) to electrical cable 90. Alternatively, sealing element 92 may be co-molded onto electrical cable 90.

[0050] The sealing element 92 of FIG. 8 encases / surrounds a middle portion of the electrical cable 90. The sealing element 92 extends laterally between opposing first and second sides 110 and 112 of the sealing element 92. The sealing element 92 extends laterally between opposing third and fourth sides 114 and 116 of the sealing element 92, each of the sealing element sides 114 and 116 extending laterally between the sealing element sides 110 and 112. Referring to FIG. 6, the sealing element 92 extends longitudinally along the centerline 98 between opposing first and second ends 118 and 120 of the sealing element 92, each of the sealing element sides 110, 112, 114 and 116 extending longitudinally between the sealing element ends 118 and 120.

[0051] The seal element 92 of FIG. 8 includes a plurality of segments 122 and 124, e.g., halves. The first seal element segment 122 is located on the third side 114 of the seal element. The second seal element segment 124 is located on the fourth side 116 of the seal element. Each seal element segment 122, 124 extends laterally between and reaches the seal element sides 110 and 112. Thus, the sides 126A and 126B, 128A and 128B of the seal element segments 122 and 124 are coplanar at the seal element sides 110, 112, respectively. Each seal element segment 122, 124 extends laterally from the respective seal element sides 114, 116 to a respective interface 130, 132. 6, each seal element segment 122, 124 (see 124 in FIG. 8) extends longitudinally between and through the ends 118 and 120 of the seal element.

[0052] Referring to FIG. 8 , the first segment 122 of the seal element is disposed adjacent to a first side 134 of the electrical cable 90. The first segment interface 130 is bonded (e.g., directly) to the electrical cable 90 / sheath 104 by a conductive adhesive, such as, for example, a conductive non-corrosive and / or pressure sensitive adhesive. Examples of conductive adhesives may include, but are not limited to, conductive silicone adhesives and conductive room temperature vulcanizing (RTV) adhesives, such as, for example, conductive RTV silicone adhesives. The second segment 124 of the seal element is disposed adjacent to a second side 136 of the electrical cable 90, as is the first segment 122 of the seal element and its interface 130. The second segment interface 132 is bonded (e.g., directly) to the electrical cable 90 / sheath 104 and the first segment interface 130 by, for example, a conductive adhesive. An intermediate portion of the electrical cable 90 is disposed (e.g., sandwiched) between the seal segments 122 and 124. Thereby, an intermediate portion of the electrical cable 90 is laterally and transversely disposed within the sealing element 92 and longitudinally covered by the sealing element 92 .

[0053] The sealing element 92 and its segments 122 and 124 may be constructed from a material adapted to block the transmission of signal noise therethrough, e.g., electromagnetic interference (EMI), such as, but not limited to, at least radio frequency (RF) signals. The sealing element 92 and its segments 122 and 124 may be constructed, for example, from a conductive polymer composite material. With reference to FIG. 9, the composite material may include a (e.g., closed cell) polymer foam 138 and a plurality of conductive (e.g., metal) particles 140 embedded within the polymer foam 138. One example of the polymer foam 138 is a (e.g., conductive, low density) urethane foam. One example of the conductive particles 140 is silver (Ag) plated copper (Cu) particles. However, the present disclosure is not limited to the aforementioned exemplary foam / particle materials. Additionally, the material of the sealing element may be adapted to block the passage of certain environmental elements, e.g., dust, moisture, and the like.

[0054] With reference to FIG. 10, each of the cable assemblies 26 is mated with a respective one of the slots 68 / openings 76A and 76B (collectively referred to as "76"). In particular, each seal element 92 and its segments 122 and 124 are disposed within a respective one of the slots 68 / openings 76. With reference to FIGS. 10 and 11, a third side 114 of each seal element engages (e.g., presses vertically) with a respective one of the slot end faces 74. A fourth side 116 of each seal element engages (e.g., presses vertically) with an inner surface 142 of the housing lid 34. With reference to FIG. 10, sides 110, 112 of each seal element engage (e.g., presses widthwise) with a respective one of the slot side faces 70, 72. Each seal element 92 thereby seals / closes a (e.g., annular) gap between a respective one of the electrical cables 90 and the electrical system housing 28. In other words, each cable assembly 26 (e.g., the combination of sealing element 92 and electrical cable 90) seals / blocks a respective one of the openings 76. With this arrangement, referring to FIG. 11 , each electrical cable 90 passes (e.g., extends, protrudes) through a respective one of the openings 76 from the first compartment 30A to the second compartment 30B, while each cable assembly 26 and its sealing element 92 prevents or reduces the transmission of undesired signals (e.g., RF signals) between the compartments 30 through their respective openings 76.

[0055] A length 144 of each sealing element 92 may be greater than a width 146 of the interior wall 40. A first portion of each sealing element 92, FIG. 11 , projects from the first side 64 of the interior wall into the first compartment 30A to an end 118. A second portion of each sealing element 92, FIG. 11 , also (or instead) projects from the second side 66 of the interior wall into the second compartment 30B to an end 120.

[0056] 12, the dimensions (e.g., width 148 and / or height 150) of each seal element 92 may be sized larger than the corresponding dimensions (e.g., width 152 and / or height 154) of each opening 76 prior to assembly of each cable assembly 26 (see FIG. 6) with electrical system housing 28 (see FIGS. 2-4). Thus, when each seal element 92 is inserted / placed within its respective slot 68 of FIGS. 10 and 11, the seal element material is compressed (e.g., slightly) and forced against housing components 32 and 34.

[0057] 5, a first portion and end of each electrical cable 90 is disposed within the first compartment 30A. A second portion and end of each electrical cable 90 is disposed within the second compartment 30B. Each of the terminals 94, 96 is mated (e.g., plugged) with a respective one of the terminals 82, 88 such that each cable assembly 26 electrically couples the first electrical component 22 in the first compartment 30A to the second electrical component 24 in the second compartment 30B.

[0058] In some embodiments, with reference to FIG. 4, each slot 68 and associated opening 76 can have a polygonal cross-sectional shape, for example, when viewed in a plane perpendicular to the length of the associated electrical cable 90 and / or the longitudinal centerline 98 of the associated cable assembly 26 (see FIG. 6), e.g., the plane of FIG. 4. The polygonal cross-sectional shape can be a rectangular cross-sectional shape as shown in FIG. 4. Alternatively, with reference to FIG. 13, the polygonal cross-sectional shape can be a (e.g., isosceles) trapezoidal cross-sectional shape. Each slot 68 can be configured, for example, as a dovetail slot. Of course, the present disclosure is not limited to the exemplary cross-sectional shapes discussed above.

[0059] In some embodiments, with reference to Figure 8, each sealing element 92 can have a polygonal cross-sectional shape, e.g., when viewed in a plane perpendicular to the length of the associated electrical cable 90 and / or the longitudinal centerline 98 of the associated cable assembly 26, e.g., the plane of Figure 8. The polygonal cross-sectional shape may be a rectangular cross-sectional shape as shown in Figure 8. Alternatively, with reference to Figure 14, the polygonal cross-sectional shape may be a (e.g., isosceles) trapezoidal cross-sectional shape. Of course, the present disclosure is not limited to the exemplary cross-sectional shapes discussed above.

[0060] In some embodiments, each seal element 92 and each associated slot 68 / opening 76 may have a similar / common cross-sectional geometry. For example, each seal element 92 may have the cross-sectional geometry of FIG. 8 or 14, and each associated slot 68 / opening 76 may have the cross-sectional geometry of FIG. 4 or 13. However, in other embodiments, at least one of the seal elements 92 may have a different cross-sectional geometry than the associated slot 68 / opening 76. For example, each seal element 92 may have the cross-sectional geometry of FIG. 8, and each associated slot 68 / opening 76 may have the cross-sectional geometry of FIG. 13. Such a configuration allows the sides 70 and 72 of each slot 68 to retain the associated cable assembly 26 during assembly (e.g., after mating with the slot 68 but prior to placement of the housing lid 34).

[0061] 15 is a flow diagram of a method 1500 for manufacturing an electrical system. For ease of explanation, the electrical system is described below as the electrical system 20 described above. However, the manufacturing method 1500 is not limited to manufacturing such an exemplary electrical system.

[0062] In step 1502, an electrical system housing 28 is provided.

[0063] In step 1504, a first electrical component 22 is provided.

[0064] In step 1506, a first electrical component 22 is placed in the first compartment 30A.

[0065] In a step 1508, a second electrical component 24 is provided.

[0066] In a step 1510, a second electrical component 24 is placed in the second compartment 30B.

[0067] In a step 1512, a first electrical cable 90A is provided.

[0068] In step 1514, the first seal element 92A is integrally formed with the first electrical cable 90A. The conductive adhesive may be applied, for example, to the first segment interface 130 of the first segment 122 of the seal element. The first electrical cable 90A may be disposed adjacent to the first segment 122 of the seal element and bonded to the first segment interface 130 by the conductive adhesive. The conductive adhesive may also be applied to the interface 132 of the second segment 124 of the seal element. This second segment 124 of the seal element may be disposed adjacent to the first electrical cable 90A and the first segment 122 of the seal element. The conductive adhesive may bond the second segment 124 of the seal element to the first electrical cable 90A as well as bond and electrically couple the second segment 124 of the seal element to the first segment 122 of the seal element. The bonded seal element segments 122 and 124 may then be cut (eg, die cut) to provide coplanar surfaces 126A and 126B, 128A and 128B on the first seal element sides 110, 112.

[0069] Adhering the first sealing element 92A to the first electrical cable 90A can secure (e.g., permanently) the first sealing element 92A to the first electrical cable 90A. The adhesion thereby forms the first sealing element 92A and the first electrical cable 90A into a single, stand-alone first cable assembly 26A. In other words, the first cable assembly 26A can be a complete unit or can be moved as a stand-alone body. This is in contrast to, for example, a separate sealing element that is placed with the cable only after the cable is placed in the housing. This is in contrast to, for example, a separate sealing element that is also used to seal the edge of the housing to the lid.

[0070] In a step 1516, a second electrical cable 90B is provided.

[0071] In step 1518, the second seal element 92B is integrally formed with the second electrical cable 90B. The conductive adhesive may be applied, for example, to the interface 130 of the first segment 122 of the seal element. The second electrical cable 90B may be disposed adjacent to the first segment 122 of the seal element and bonded to the first segment interface 130 by the conductive adhesive. The conductive adhesive may also be applied to the interface 132 of the second segment 124 of the seal element. This second segment 124 of the seal element may be disposed adjacent to the second electrical cable 90B and the first segment 122 of the seal element. The conductive adhesive may bond the second segment 124 of the seal element to the second electrical cable 90B as well as bond and electrically couple the second segment 124 of the seal element to the first segment 122 of the seal element. The bonded seal element segments 122 and 124 can then be cut (eg, die cut) to provide coplanar surfaces 126A and 126B, 128A and 128B on the sides 110, 112 of the second seal element.

[0072] The bonding of the second sealing element 92B to the second electrical cable 90B can secure (e.g., permanently) the second sealing element 92B to the second electrical cable 90B. The bonding thereby forms the second sealing element 92B and the second electrical cable 90B into a single, stand-alone second cable assembly 26B. In other words, the second cable assembly 26B can be a complete unit or can be moved as a stand-alone body. This is in contrast to, for example, a separate sealing element that is placed with the cable only after the cable is placed in the housing. This is in contrast to, for example, a separate sealing element that is also used to seal the edge of the housing to the lid.

[0073] In step 1520, each cable assembly 26 is electrically coupled to first electrical component 22 and second electrical component 24, for example as described above.

[0074] In step 1522, the first cable assembly 26A and the second cable assembly 26B are positioned with the electrical system housing 28. For example, the first seal element 92A may be installed within the first slot 68A as described above. Similarly, the second seal element 92B may be installed within the second slot 68B as described above. The housing lid 34 may then be attached to the housing base 32, thereby sandwiching each seal element 92 between the housing lid 34 and the housing base 32 and its interior wall 40.

[0075] Although various embodiments of the present disclosure have been described, it will be apparent to those skilled in the art that many more embodiments and implementations are possible within the scope of the present disclosure. For example, the present disclosure described herein includes several aspects and embodiments that include specific features. Although these features can be described individually, it is within the scope of the present disclosure that some or all of these features can be combined with any one of the aspects to remain within the scope of the present disclosure. Thus, the present disclosure should not be limited except in light of the appended claims and their equivalents.

Claims

1. 1. An assembly for an electrical system, comprising: a housing including a wall; an electrical cable passing through the wall opening; a sealing element surrounding the electric cable and integral with the electric cable, the sealing element comprising a conductive polymer composite material; Including, the sealing element is positioned within the opening, the opening configured as a dovetail slot in the wall, the sealing element being sized larger than a dimension of the opening to fill an annular gap between the electrical cable and the housing and having a trapezoidal cross-sectional shape that fits into the dovetail slot.

2. The assembly of claim 1 , wherein the electrical cable is configured as a flexible ribbon cable.

3. the electrical cable includes a sheath and a conductor within the sheath; the sealing element is bonded directly to the sheath; The assembly of claim 1 .

4. The assembly of claim 1 , wherein the conductive polymer composite material comprises a polymer foam and a plurality of metal particles embedded within the polymer foam.

5. The assembly of claim 1 , wherein the conductive polymer composite is configured to block the transmission of radio frequency (RF) signals.

6. the sealing element includes a first segment and a second segment; the electrical cable is between the first segment and the second segment; The assembly of claim 1 .

7. The assembly of claim 1 , further comprising a conductive adhesive for adhering the sealing element to the electrical cable.

8. the wall has a first side and a second side, the opening extending through the wall between the first side and the second side; and, a first portion of the sealing element protruding from the first surface; or a second portion of the sealing element protruding from the second surface; At least one of The assembly of claim 1 .

9. the housing further comprising a lid; the sealing element is sandwiched between the wall and the lid; The assembly of claim 1 .

10. the housing is configured with a first compartment and a second compartment; the wall is between the first compartment and the second compartment; a first end of the electrical cable is within the first compartment; a second end of the electrical cable within the second compartment; The assembly of claim 1 .

11. 1. An assembly for an electrical system, comprising: a housing including a first compartment, a second compartment, and a wall between the first compartment and the second compartment that defines the first compartment and the second compartment, the wall being configured with an opening; a cable assembly including an electrical cable and a sealing element, the cable assembly being configured to prevent transmission of at least radio frequency signals through the opening; Including, the electrical cable extends through the opening into the first compartment and the second compartment; the sealing element is placed in the opening and adhered to the electrical cable, the opening being configured in the wall as a dovetail slot, the sealing element being sized larger than a dimension of the opening to fill a gap between the electrical cable and the housing and having a trapezoidal cross-sectional shape that fits into the dovetail slot. assembly.

12. The assembly of claim 11 , wherein the sealing element surrounds the electrical cable.

13. The assembly of claim 11 , wherein the sealing element comprises a conductive polymer composite material.

14. the sealing element includes a first segment and a second segment, the first segment and the second segment being disposed within the opening; the electrical cable is between the first segment and the second segment; 12. The assembly of claim 11.

15. A manufacturing method comprising the steps of: forming a sealing element integrally with an electrical cable to provide a cable assembly; placing the cable assembly with a housing, the housing including a wall and an opening extending through the wall and configured as a dovetail slot in the wall, the electrical cable protruding through the opening, the sealing element configured to have a trapezoidal cross-sectional shape sized larger than a dimension of the opening and fitting into the dovetail slot and disposed within the opening such that the cable assembly closes the opening to prevent at least transmission of radio frequency signals through the opening; A manufacturing method comprising:

16. the sealing element includes a first segment and a second segment; forming the sealing element includes adhering the electrical cable to the first segment and the second segment, the electrical cable being between the first segment and the second segment; The method of claim 15.

17. The method of claim 15 , wherein the sealing element comprises a conductive polymer composite material.

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