Liquid-Tight Seal for Vehicle Cable Assembly Corrosion
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Solution Overview
Problem
The increasing size and weight of vehicle electrical systems due to numerous consumers lead to parallel laying of electrical lines with the same potential, resulting in corrosion and premature failure when different metallic materials are used in conjunction with an electrolyte, especially at tapping points in the main supply lines.
Innovation Solution
A line arrangement for an on-board network that encloses the power distributor and main supply line in a liquid-tight manner on the outside at the contacting area, preventing electrolyte penetration and thus corrosion, allowing energy distribution not only at line ends but also between them, using inexpensive stamped and bent parts and various sealing methods like shrink tubes or foam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If power distributors and main supply line are made of different metallic materials to enable flexible energy distribution, then adaptability and ease of manufacture are improved, but contact corrosion occurs due to electrolyte penetration at contacting areas
Solution Approach 1:
A seal is introduced as an intermediary element between the power distributor and main supply line at the contacting area. This seal creates a liquid-tight enclosure that prevents electrolyte penetration, thereby protecting the different metallic materials from galvanic corrosion while still allowing them to be in electrical contact for power distribution.
Solution Approach 2:
The seal creates a protected environment around the contacting area, excluding the electrolyte (corrosive environment). By creating this inert/protected space, the different metallic materials can coexist without undergoing harmful electrochemical reactions, thus maintaining reliability while allowing material versatility.
2Adaptability or versatility
If parallel laying of electrical lines is implemented to supply multiple consumers, then energy distribution capability is improved, but system weight and complexity increase
Solution Approach 1:
The patent merges multiple electrical lines into a single main supply line by using power distributors with integrated tapping points. Instead of laying separate parallel lines from the power source to each consumer, multiple consumers can be connected to one main line through the power distributor, reducing overall system weight while maintaining distribution capability.
Solution Approach 2:
The main supply line serves multiple functions: it provides power to multiple consumers simultaneously through the power distributor's tapping points. This multi-functional design eliminates the need for separate dedicated lines for each consumer, reducing system complexity and weight while maintaining full energy distribution capability.
3Ease of manufacture
If power distributors are connected directly to main supply line without sealing, then ease of installation is improved, but contact corrosion leads to premature failure
Solution Approach 1:
The seal is pre-applied or pre-positioned on the power distributor or main supply line before connection. This preliminary protective measure ensures that as soon as the electrical connection is made, the contacting area is already protected from electrolyte penetration, preventing corrosion from the outset and ensuring long service life without complicating the installation process.
Solution Approach 2:
The seal acts as a protective intermediary that is easily integrated into the connection process. It provides the necessary corrosion protection without requiring complex installation procedures, thus maintaining ease of installation while dramatically extending the service life of the electrical connection by preventing galvanic corrosion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively prevents corrosion and allows for energy distribution along the main supply line, reducing material requirements and costs while maintaining reliable electrical connections, even with different metallic material pairings, and supports various configurations including round or flat conductors and multi-busbar designs.
Implementation Method 1
the power distributor and the main supply line being at least in the contacting area enclosed on the outside in a liquid-tight manner by the seal
Data Source
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AI summary
The invention relates to a wiring arrangement (10) for the electrical system of a motor vehicle, comprising a main supply line (12) for the electrical system and at least one power distributor (18) for tapping current for at least one consumer, which is electrically connected to the main supply line (12) at at least one stripped contact area (20), wherein the power distributor (18) and the main supply line (12) are enclosed on the outside, at least in the contact area (20), by a liquid-tight seal (22, 46). The invention further relates to a method for manufacturing a wiring arrangement (10) for the electrical system of a motor vehicle.