Elastomeric Hose Sealing for Conductor Joints
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Solution Overview
Problem
Existing methods for sealing the connection point between electrical conductors and contact elements in automotive electronics are inadequate, leading to exposure to environmental influences and potential corrosion, especially due to gaps caused by crimping or welding processes, which can result in increased contact resistance and short circuits.
Innovation Solution
A method using an elastic hose section made of insulating material, such as neoprene, is applied around the conductor insulation and contact element, utilizing its elastic forces to create a media-tight seal by being pressed firmly against both, effectively sealing the connection point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shrink tube with hot-melt adhesive is used to seal the connection point, then the connection point is sealed against environmental influences, but the material connection is not optimally resistant to strong temperature fluctuations
Solution Approach 1:
The patent changes the material parameter from thermoplastic (shrink tube with adhesive) to elastomeric (thermosetting rubber compound). The elastomeric material maintains its sealing properties across a wide temperature range (-40°C to +125°C) without the temperature-related degradation that plagues thermoplastic adhesives.
Solution Approach 2:
The sealing element uses a composite structure combining an elastomeric base material with integrated conductive particles (carbon black or metal particles). This composite provides both electrical conductivity and environmental sealing, eliminating the need for separate adhesive layers that fail under temperature stress.
2Reliability
If the connection point is overmolded with plastic in injection molding process, then the connection point is sealed and insulated, but the process is relatively time-consuming and expensive
Solution Approach 1:
The sealing function is separated from the insulation function. The elastomeric sealing element is a discrete component that can be pre-formed and then applied to the connection point, rather than requiring a complex multi-step injection molding process to create an integrated seal.
Solution Approach 2:
The sealing element is pre-formed with the correct geometry and properties before application. This eliminates the need for complex real-time molding operations at the connection point, significantly reducing manufacturing time and complexity.
3Ease of manufacture
If single wire seal is crimped around conductor insulation, then the process is simpler, but the connection point itself between stripped conductor end and cable lug is not sealed
Solution Approach 1:
The elastomeric sealing element is designed to nest over the existing crimped connection, enveloping the connection point between the conductor and cable lug. This nested structure provides sealing for the previously exposed connection without requiring redesign of the crimping process itself.
4Reliability
If elastic hose section is applied around conductor insulation and contact element, then the connection point is reliably sealed against moisture and media, but additional components are required
Solution Approach 1:
The elastomeric sealing element performs multiple functions simultaneously: it seals the connection point against environmental ingress, provides electrical insulation, and maintains flexibility for vehicle movement. This consolidates what would otherwise require multiple separate components into a single multi-functional element.
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 method provides a reliable, cost-effective, and efficient means to seal the connection point, suitable for individual conductors and series production, preventing moisture and corrosion, thereby enhancing the durability and reliability of electrical connections.
Implementation Method 1
utilizing its elastic forces to create a media-tight seal by being pressed firmly against both
Data Source
Figure 1~3
Figure 4A~5
AI summary
A method for sealing the connection between an electrical conductor (1) surrounded by insulation (2) and a tubular electrical contact element (3) connected to the conductor (1) is described. First, the insulation (2) is removed from the end of the conductor (1), and then the contact element (3) is placed onto the conductor (1) and electrically connected to it. Before placing the contact element (3) onto the conductor (1), a section of flexible insulating tubing (8) is applied with one end (9) firmly in contact with the insulation (2) of the conductor (1), with the second end (10) of the tubing being bent over the first end (9). The contact element (3) is then electrically connected to the conductor (1) in the area adjacent to the insulation (2) of the conductor (1), while maintaining its tubular shape.The bent second end (10) of the hose piece (8) is then bent back over the contact element (3) while firmly attached to it.