Ribbon-to-Round Cable Transition Sealing Against Moisture Ingress
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Solution Overview
Problem
Existing electrical line connections in composite panes, particularly those transitioning from flat ribbon cables to round cables, face issues with moisture penetration due to sealing failures, leading to potential interference and damage.
Innovation Solution
An electrical line connection with a cross-sectional transition region using a flat ribbon cable and a round cable, featuring a first and second sealing means, where the first sealing means is a double-sided adhesive tape on the flat ribbon cable and the second sealing means is a ring-shaped collar on the round cable, both ensuring a watertight encapsulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flat ribbon conductors are soldered to connection surfaces and guided away over the edge where they are connected to a round cable, then electrical connection is achieved, but moisture penetration occurs due to sealing failure at the junction
Solution Approach 1:
The sealing system is divided into multiple segments: a first sealing means (adhesive tape) applied to the flat ribbon cable and a second sealing means (collar) applied to the round cable. This segmentation allows each sealing component to address specific sealing challenges at different locations, preventing moisture penetration through coordinated multi-point sealing rather than relying on a single sealing point that might fail
Solution Approach 2:
The encapsulation made of insulating material serves as an intermediary structure that houses both the electrical connection and the sealing means. It provides a protective environment that combines electrical insulation with moisture protection, mediating between the electrical connection requirements and the sealing requirements by integrating both functions within a single encapsulated assembly
2Reliability
If the encapsulation is attached to the line connection, then electrical insulation is provided, but moisture can still penetrate into the encapsulation through sealing failures
Solution Approach 1:
The patent merges the electrical insulation function and the moisture protection function into a single integrated encapsulation structure. The encapsulation simultaneously provides electrical insulation for the conductor connection and houses the sealing means to prevent moisture ingress, combining two protective functions that were previously separate concerns into one unified solution
3Device complexity
If a single sealing method is used at the cable junction, then the structure is simple, but sealing effectiveness is insufficient to prevent moisture penetration
Solution Approach 1:
The sealing approach is segmented into two distinct sealing means applied at different locations: adhesive tape on the flat ribbon cable and a collar on the round cable. This segmentation increases sealing effectiveness by creating multiple barrier points against moisture while maintaining relatively simple individual components that can be applied using standard techniques
Solution Approach 2:
The sealing system employs composite sealing approaches: the first sealing means uses adhesive tape (combining adhesive material with carrier film), and the second sealing means uses a collar structure. These composite sealing solutions provide enhanced sealing effectiveness compared to single-material approaches, combining different material properties to achieve reliable moisture protection
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
The solution provides a secure and permanently watertight seal, preventing moisture ingress and enhancing the durability and reliability of the electrical connection.
Implementation Method 1
The first sealing means is a double-sided adhesive tape which is arranged on two opposite surfaces of the flat ribbon cable
Implementation Method 2
Such an arrangement of the sealing means (seals) ensures that the penetration of water into the encapsulation, by a capillary effect, is prevented
Data Source
AI summary
An electrical line connection having a cross-sectional transition region from a flat ribbon cable to a cable, in particular a round cable, wherein, in the cross-sectional transition region, an electrical connection between the conductor track of the flat ribbon cable and the conductor of the cable is provided, wherein the cross-sectional transition region has an encapsulation for electrical insulation, wherein a first sealing device is provided on the flat ribbon cable and a second sealing means is provided on the cable, wherein the first sealing device is a double-sided adhesive tape which is arranged on two opposite surfaces of the flat ribbon cable and wherein the second sealing device has one, two or more sealing lips.