Moisture-Proof Sealing for Electrical Conductor Connection Points
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Solution Overview
Problem
Existing methods for sealing connection points between electrical conductors and contact elements in harsh environments, such as vehicle engine compartments, fail to effectively prevent moisture ingress due to insufficient penetration of sealing materials between individual wires and insulation, leading to potential short circuits and corrosion.
Innovation Solution
A method involving the placement of an insulation foil underneath the connection point, followed by the application of a flowable sealing material that hardens, ensuring the material penetrates into the gap between the conductor and insulation, and is stabilized by adhering to the foil and contact element, forming a comprehensive seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If injection molding material or sealing material of a hose is used to protect the connection point, then the connection point is covered and protected, but the sealing material does not penetrate sufficiently deeply between the individual wires of the strand, leaving gaps unsealed
Solution Approach 1:
A foil is positioned underneath the connection point before applying the sealing material. This preliminary placement creates a border that directs and forces the sealing material to penetrate deeply between the individual wires of the strand, ensuring complete sealing of gaps that would otherwise remain unsealed.
Solution Approach 2:
The foil acts as an intermediary element between the sealing material and the connection point. It serves as a border and support structure that guides the sealing material into the gaps between wires, enabling effective penetration and sealing without requiring complex application methods.
2Ease of manufacture
If a simple cover is placed over the connection point, then the manufacturing process is simple, but moisture can penetrate through gaps between the conductor and insulation
Solution Approach 1:
The foil is positioned in advance underneath the connection point before the sealing material is applied. This simple preliminary step creates a border that ensures the sealing material penetrates into gaps between the conductor and insulation, preventing moisture penetration while maintaining manufacturing simplicity.
Solution Approach 2:
The sealing material is applied in a flowable state to specifically target and fill the gaps between the conductor and insulation where moisture penetration would occur. The foil border ensures this localized sealing action occurs precisely where needed, protecting against moisture while keeping the overall method simple.
3Reliability
If sealing material is applied to ensure deep penetration between wires, then sealing effectiveness improves, but the quantity of material required increases
Solution Approach 1:
The foil acts as an intermediary border that confines and directs the sealing material into the gaps between individual wires. This border effect ensures that the sealing material penetrates deeply and completely seals all gaps without requiring excessive quantities of material, as the foil prevents lateral spreading and focuses the material where it is most needed.
Solution Approach 2:
By positioning the foil beforehand, the path for sealing material penetration is pre-defined and constrained. This preliminary action ensures that when sealing material is applied, it flows efficiently into the gaps between wires and is contained by the foil border, achieving complete sealing with optimal material quantity.
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 approach creates a stable, moisture-proof seal around the connection point, effectively preventing moisture ingress and ensuring the longevity of the electrical connection by filling the gap between the conductor and insulation.
Implementation Method 1
a sealing material capable of hardening is applied from above onto the strand, wherein the sealing material is flowable when being applied and subsequently changes over into a mechanically stable state by hardening
Implementation Method 2
the contact element extends beyond the insulation of the strand and is tightly connected to the foil
Implementation Method 3
a foil of insulation material is positioned underneath the connection point, wherein the insulation foil, adheres, at least partially, to the contact element
Data Source
AI summary
A method is disclosed for moisture tight covering a connection point between an electrical conductor. The method includes exposing the conductor at its end by removing the insulation and subsequently electrically conductively connecting the end of the conductor, from which the insulation has been removed, to the contact element. After the connection point is finished, a foil of insulation material is positioned underneath the connection point, where the foil rests against the insulation of the conductor and at least partially against the contact element. Subsequently, a sealing material capable of hardening is applied from above onto the conductor, wherein the sealing material is flowable during its application and subsequently changes over by hardening into a mechanically stable state which extends beyond the insulation of the conductor and beyond the contact element and is connected tightly to the foil.