External Sealing Elements for Electrical Line Connections
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Solution Overview
Problem
Existing electrical conductor connection arrangements in motor vehicles, particularly those with silicone or cross-linked polymer insulation, face challenges in achieving a moisture-tight seal without bonding the injection material to the insulation, and struggle with mechanical integrity due to the need for overmolding which complicates the use of certain insulation materials.
Innovation Solution
The solution involves using sealing elements outside the insulating body, made of materials like silicone or EPDM, which are media-tightly applied to the insulation and secured by protective elements, allowing for a compact, moisture-tight connection without the need for overmolding, and enabling the use of insulation materials that cannot be tightly bonded with conventional injection materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional overmolding is used to create a moisture-tight seal, then the seal is moisture-proof, but the injection material cannot bond to silicone or cross-linked polymer insulation
Solution Approach 1:
The sealing function is segmented from the insulating body. The closure element is divided into a first sealing portion (contacting the line insulation) and a second sealing portion (contacting the insulating body), allowing each portion to be optimized for its specific bonding requirement without conflict
Solution Approach 2:
The first sealing portion of the closure element acts as an intermediary between the line insulation and the insulating body. It provides a bonding interface to the line insulation that is compatible with silicone or cross-linked polymers, while the second sealing portion provides the moisture-tight seal against the insulating body
2Reliability
If sealing elements are arranged inside the insulating body, then the connection is moisture-tight, but the insulating body becomes larger and less compact
Solution Approach 1:
The sealing elements (closure elements) are extracted from the interior of the insulating body and positioned at the outer surface. This allows the insulating body to maintain a compact, space-saving geometry while the closure elements provide the moisture-tight seal at the interface with the lines
Solution Approach 2:
The closure elements function as flexible sealing components that can be positioned at the surface of the insulating body, creating an effective barrier against moisture without requiring internal volume
3Strength
If the insulating body is made compact and space-saving, then mechanical strength against vibration is improved, but the sealing capability may be compromised
Solution Approach 1:
The closure element is segmented into distinct sealing portions, allowing the second sealing portion to be optimized for creating a moisture-tight seal against the compact insulating body, while the overall compact geometry maintains mechanical strength
Solution Approach 2:
The sealing capability is maintained through changes in the parameters of the closure element (material properties, geometric configuration of sealing portions) rather than increasing the size of the insulating body
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 ensures a compact, space-saving, and mechanically robust connection that withstands vibrations and moisture, allowing for flexible production processes and compatibility with various insulation materials, enhancing the reliability of electrical connections in harsh vehicle environments.
Implementation Method 1
the passages of the lines into the insulating body are sealed in a media-tight manner by means of the closure elements
Implementation Method 2
the sealing elements applied to the insulation of the lines are arranged outside of the injected insulating body and are secured by protective elements
Data Source
Figure 1~2
AI summary
An arrangement for the electrically conductive connection of at least two electrical conductors (2, 3, 4), each surrounded by insulation, is described. The arrangement comprises an insulating body (1) manufactured by injection molding, which encloses the connection points between the conductors of the conductors (2, 3, 4). A sealing element (12, 13) is slid onto each of the conductors (2, 3, 4) to be electrically connected. This sealing element has a sealing element (12) and a protective element (13) firmly surrounding it, and it forms a media-tight seal against the insulation of the conductor (2, 3, 4) all around. The insulating body (1) has a tube-like projection (9, 10, 11) on the areas surrounding the conductors (2, 3, 4). In the assembled state, the sealing element (12) is arranged outside the insulating body (1) on each line (2, 3, 4) and is connected to the projections (9, 10, 11) of the insulating body (1) in a media-tight manner by means of the protective element (13).Further procedures for manufacturing the arrangement are specified.