METHOD AND DEVICE FOR SEALING CONTACT POINTS AT ELECTRICAL LINE CONNECTIONS

Abstract

The invention relates to a method for sealing a contact point region comprising at least one contact point at an electrical line connection, wherein the line connection comprises at least one electrical line and at least one conductive element electrically connected thereto. The method starts by arranging a shrink tube on the outer circumference of the contact point region, in a first region extending over the contact point region on both sides in the longitudinal direction. This is followed by heating the shrink tube to shrinking temperature. During the heating of the shrink tube, an inductive heating of the electrical conductor is additionally performed, at least in the contact point region, and so hotmelt adhesive arranged inside the shrink tube and/or on the outer circumference of the contact point region is heated to its melting temperature. The invention also relates to a device for sealing a contact point region and to a sealing at such a region.

Claims

1. A method for sealing a contact point area, having at least one contact point, at an electrical line connection, the line connection including at least one electrical line and at least one electrical conductive element connected thereto, the electrical line having at least one electrical conductor with conductor insulation, which, however, is removed in the contact point area, comprising the following steps: arranging a heat shrink tube on the outer circumference of the contact point area in a first area that extends in the longitudinal direction beyond the contact point area on both sides; heating the heat shrink tube to the shrinkage temperature from the outside via a heat source; and during the heating of the heat shrink tube, generation of a magnetic field for inductive heating of the electrical conductor additionally takes place, at least in the contact point area, so that hot-melt adhesive situated inside the heat shrink tube and/or on the outer circumference of the contact point area is heated to its melting temperature.

2. The method according to claim 1, wherein the electrical conductor is inductively heated in the contact point area in such a way that the temperature on its outer circumference and also in its core is greater than or equal to the melting temperature of the hot-melt adhesive.

3. The method according to claim 1, wherein the heating of the heat shrink tube to the shrinkage temperature takes place via externally applied hot air and/or irradiated infrared radiation.

4. The method according to claim 1, wherein during the heating of the heat shrink tube, inductive heating of the electrical conductor also takes place in a second area adjoining the contact point area, so that the conductor insulation in this area is heated to its melting temperature.

5. The method according to claim 1, wherein hot-melt adhesive is applied at least in the contact point area before the heat shrink tube is arranged.

6. The method according to claim 1, wherein a heat shrink tube having an inner coating of hot-melt adhesive is situated at the contact point area.

7. The method according to claim 1, wherein hot-melt adhesive having a melting temperature that is in the melting temperature range of the conductor insulation is applied, at least in the contact point area, and/or is guided over the heat shrink tube at the contact point area.

8. The method according to claim 1, wherein an outer border area of the heat shrink tube is cooled while the heat shrink tube and the electrical conductor are being heated.

9. The method according to claim 1, wherein the heat shrink tube is situated at the contact point area of a line connection which has at least one electrical line and an electrically conductive element that is designed as an electrical connector or electrical terminal contact.

10. A device for sealing a contact point area, having at least one contact point, at an electrical line connection, the line connection including at least one electrical line that has at least one electrical conductor with conductor insulation, and at least one electrically conductive element that is connected to the electrical line, wherein the electrical conductor of the electrical line has no conductor insulation in the contact point area, wherein the device includes a heat source for heating the heat shrink tube to the shrinkage temperature from the outside, and additionally includes an induction unit for inductively heating the electrical conductor, at least in the contact point area, to the melting temperature of the hot-melt adhesive.

11. The device according to claim 10, wherein it also has a cooling device for cooling the outer border areas of the heat shrink tube.

12. The device according to claim 10, wherein the heat source for heating the heat shrink tube to the shrinkage temperature from the outside provides hot air and/or infrared radiation.

13. The device according to claim 11, wherein the heat source for heating the heat shrink tube to the shrinkage temperature from the outside provides hot air and/or infrared radiation.

14. The method according to claim 3 wherein during the heating of the heat shrink tube, inductive heating of the electrical conductor also takes place in a second area adjoining the contact point area-, so that the conductor insulation in this area is heated to its melting temperature.

15. The method according to claim 2 wherein an outer border area of the heat shrink tube is cooled while the heat shrink tube and the electrical conductor are being heated.

16. The method according to claim 3 wherein an outer border area of the heat shrink tube is cooled while the heat shrink tube and the electrical conductor are being heated.

17. The method according to claim 4 wherein an outer border area of the heat shrink tube is cooled while the heat shrink tube and the electrical conductor are being heated.

18. The method according to claim 5 wherein an outer border area of the heat shrink tube is cooled while the heat shrink tube and the electrical conductor are being heated.

19. The method according to claim 6 wherein an outer border area of the heat shrink tube is cooled while the heat shrink tube and the electrical conductor are being heated.

20. The method according to claim 7 wherein an outer border area of the heat shrink tube is cooled while the heat shrink tube and the electrical conductor are being heated.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Preferred applications of the method according to the invention are explained in greater detail below with reference to the appended drawings. Also described in greater detail are the individual method steps that are carried out to provide these preferred applications. The drawings show the following:

[0029] FIG. 1 shows a sealed contact point area of a line connection according to a first embodiment;

[0030] FIG. 2 shows a sealed contact point area of the line connection according to a second embodiment;

[0031] FIG. 3 shows a sealed contact point area of the line connection according to a third embodiment;

[0032] FIG. 4 shows a sealed contact point area of the line connection according to a fourth embodiment;

[0033] FIG. 5 shows a sealed contact point area of the line connection according to a fifth embodiment;

[0034] FIG. 6 shows a schematic illustration of a device for producing the sealed contact point area according to FIG. 5, together with the resulting temperature curve; and

[0035] FIG. 7 shows a diagram of the essential process steps for producing the sealed contact point area.

DETAILED DESCRIPTION

[0036] The line connections 02 shown in the figures each include at least one electrical line 03 and an electrically conductive element that is connected to the electrical line 03. The electrically conductive element may be designed as an electrical conductor 04, an electrical connector 12, or an electrical terminal contact 14, for example.

[0037] FIG. 1 shows a sealed contact point area 01 of a line connection 02 according to a first embodiment. The line connection 02 includes two electrical lines 03. The electrical lines 03 each have an electrical conductor 04 with conductor insulation 05. Both lines 03 are connected to one another in the contact point area 01. The electrical conductors 04 have no conductor insulation 05 in the contact point area 01. There is preferably a weld joint, produced by ultrasonic welding, for example, between the two electrical conductors 04. In the exemplary embodiment shown, the lines 03 each have one electrical conductor 04. Of course, the lines 03 may also include multiple conductors 04. The conductors 04 are preferably stranded wire conductors. Likewise, multiple lines 03 that are connected to one another in the contact point area 01 may also be situated on one or both sides. Alternatively, this could be a continuous electrical line 03 that is free of conductor insulation 05 in the contact point area 01.

[0038] For clarification, it is pointed out that the type of electrical conductor and the type of connection are not important for implementing the invention. In the simplest case, the electrical line may also be a one-piece continuous line whose insulation in one section has been removed or damaged, so that there is an exposed contact point area at which a seal according to the invention is to be produced.

[0039] A heat shrink tube 07 that extends on the outer circumference of the contact point area 01 in a first area 08 that runs in the longitudinal direction of the contact point area 01 is used for sealing the contact point area 01 of the line connection 02. The first area 08 extends beyond the contact point area 01 on both sides.

[0040] The seal on the contact point area 01 is produced via the method according to the invention, as described below. The heat shrink tube 07 is arranged on the outer circumference of the contact point area 01 in a first step. The length of the heat shrink tube is selected so that the heat shrink tube 07 extends beyond the contact point area 01 on both sides. The heat shrink tube 07 preferably has an inner coating of hot-melt adhesive. Additionally or alternatively, prior to arranging the heat shrink tube 07, hot-melt adhesive may be applied directly to the contact point area 01 or positioned on the contact point area 01 in the form of a hot-melt adhesive molding. The hot-melt adhesive preferably has a processing temperature in the melting range of the conductor insulation 05.

[0041] The heat shrink tube -07 is subsequently heated to the shrinkage temperature, preferably by hot air or infrared radiation. During the heating of the heat shrink tube 05 [sic; 07], the electrical conductors 04 at the same time are inductively heated, at least in the contact point area 01. The hot-melt adhesive present in the contact point area 01 is thereby heated to its processing temperature, and the hot-melt adhesive meets the preheated conductor material, so that the flowability of the adhesive is maintained and the adhesive is thus able to penetrate into all cavities and provide a good sealing effect.

[0042] While carrying out the method according to the invention, in the contact point area 01 the conductor material may be heated to temperatures in the range of 210 to 300 C., for example. In the second area 09, the temperature of the conductor 04 should still be high enough that melting of the conductor insulation 05 is possible in the second area 09. In contrast, in the outer border area 10, the aim is for the temperature to be low enough that no damage results to the conductor insulation 05 in this area. For this purpose, the temperature in the outer border area 10 should preferably be below the melting range of the conductor insulation 05. The outer border area 10 may be additionally cooled, for example with cold air, in order to control the temperature at the border area to an appropriately low level. Cooling may be dispensed with when, due to the temperature gradient, the temperature in the outer border area 10 is already below the melting range of the conductor insulation 05.

[0043] FIG. 2 shows a sealed contact point area 01 of the line connection 02 according to a second embodiment. The present line connection 02 includes electrical lines 03 that are connected via an electrical connector 12. Three electrical lines 03 are connected to a first side of the electrical connector 12, whereas two electrical lines 03 are connected to an opposite second side of the electrical connector 12. The electrical connector 12 is designed as a through connector. The electrical lines 03 each have an electrical conductor 04 that is provided with conductor insulation 05. Original conductor insulation 05 is no longer present in the contact point area 01. The sealing, and thus at the same time the electrical insulation, of the contact point area 01 of the line connection once again takes place by means of the heat shrink tube 07.

[0044] FIG. 3 shows a sealed contact point area 01 of the line connection 02 according to a third embodiment. The illustrated line connection 02 contains three electrical lines 03 that are connected to an electrical connector 12 by ultrasonic welding or by means of a crimp barrel, for example. The electrical connector 12 is designed as an end connector. The electrical lines 03 are connected to the same side of the electrical connector 12. The heat shrink tube 07 used for sealing and insulation of the contact point area 01 has an extension 13 which extends beyond the electrical connector 12 and which has a smaller diameter than the heat shrink tube 07 in the contact point area 01.

[0045] For producing the sealed contact point area 01 illustrated in FIG. 3, the heat shrink tube 07 is heated as described above. At the same time, the electrical conductor 04 is inductively heated in the contact point area 01. As a result of heating the conductor 04 and heat shrink tube 07, the hot-melt adhesive present at the contact point area 01 is brought to its processing temperature, and is thus able to penetrate into all cavities to be sealed. The heating results in melting of the conductor insulation 05 in the second area 09 adjoining the contact point area 01, thereby achieving additional sealing in the second area 09. However, the outer border area 10 adjoining the second area 09 is not damaged, since the temperature at that location is kept lower.

[0046] FIG. 4 shows a sealed contact point area 01 of the line connection 02 according to a fourth embodiment. The line connection 02 includes an electrical line 03 that is connected to an electrical terminal contact 14. The electrical terminal contact 14 may be a cable lug or a crimp contact, for example. A heat shrink tube 07 is used once again for the sealing.

[0047] FIG. 5 shows a modified embodiment of the line connection. The electrical connector 12 is once again situated between the total of four electrical lines 03 (two on each side) in order to electrically connect all electrical conductors 04 to one another. The contact point area 01 includes the electrical connector 12, in the present case an ultrasonically welded section, and the stripped sections of the electrical conductors 04. The length and width of the electrical connector 12 result from the particular specifications for the application, taking into account the welding machine used. The hot-melt adhesive used is introduced into the cavities between the conductors in the contact point area 01. The aim is to achieve a capillary seal; this is possible only via the introduction of adhesive in this area. In the example illustrated here, the second area 09 is divided into a primary sealing area 09a and a secondary sealing area 09b. In the primary sealing area 09a adjoining the outer border area 10, the hot-melt adhesive provides for gluing of the heat shrink tube 07 to the conductor insulation 05. Due to the heating of the conductor insulation 05, gas-tight melting of the insulation material between the individual electrical lines 04 also occurs in the secondary sealing area 09b adjoining the contact point area 01. For this purpose, a heat input profile is created with the aid of the inductor and optional lateral cooling air; the heat input profile results in a higher temperature in the secondary sealing area 09b than in the primary sealing area 09a, the temperature in the secondary sealing area 09b being determined by the melting temperature of the insulation material. In the secondary sealing area 09b the line insulation 05 fuses together, resulting in a seal between the lines 03. On the outer circumference, the line insulation in this section forms a shared insulation sheathing, which toward the outside is joined to the hot-melt adhesive. The hot-melt adhesive seals between the heat shrink tube 07 and the shared insulation sheathing of the line bundle.

[0048] In the border area 10, the temperature during the process is instead selected so that no change in the mechanical and optical properties of the insulation occurs. Neither curing of the insulation nor melting or crack formation is desired in this section. This temperature control is achieved by the inductor supplying little or no energy in the border area 10, and if necessary, cooling by supplying cooling air.

[0049] FIG. 6 shows a schematic illustration of a device for producing the sealed contact point area as illustrated in FIG. 5. A hot air feed 20 which conducts heated air 21 onto the section of the heat shrink tube 07 to be heated is situated above the line connection 02. Alternatively or additionally, infrared radiation could be used. To avoid an undesirable temperature increase in the outer border area, a section of cooling air feed 22 through which cool air 23 is blown in is situated on both the right side and the left side of the hot air feed 20. Lastly, an inductor 24 is provided, having a design that is generally known and used for the input of inductive energy into the electrical conductor. FIG. 6 also schematically shows the curve of the temperature T that results from use of the described device during the heating of the line connection in its individual sections.

[0050] The diagram illustrated in FIG. 7 summarizes the essential process steps that are carried out for producing the sealed contact point area. The line connection in the above-described device is inserted and clamped in place in preparatory steps 30, 31. During the actual shrinkage and sealing process 32, the following steps proceed in chronological order: Optional preheating may take place, if necessary, in step 33. This is always advisable when the air gap between the heat shrink tube and the electrical line is large, and the aim of the preheating is to place the heat shrink tube against the line. The induction heating is initiated in subsequent step 34. At essentially the same time, the heat shrink tube and the hot-melt adhesive are heated by hot air, for example, in step 35. The electrical conductor is heated primarily by induction, which melts the conductor insulation. Due to the external heating, the heat shrink tube is heated and then shrinks, and the necessary pressure is generated for fusing the melted conductor insulation and pressing the adhesive into the cavities. Thorough heating of the heat shrink tube takes place in subsequent step 36. Due to the required thermal gradient toward the outside, after the induction it is possible that the heat shrink tube does not make correct contact, in particular in the outer boundary zones. To guarantee contact, by means of conventional heating the tube is shrunk into its required shape and air inclusions are forced out. Thus, during steps 35 and 36, conventional heating takes place continuously via a hot air feed, for example. Even during the conventional heating it may be advantageous to carry out optional cooling in step 37. Cooling of the boundary zones is necessary to achieve the required thermal gradient with a complex line connection. The copper material customarily used as an electrical conductor has good heat conduction, and quickly carries the heat to the outside. For thick copper cross sections, without cooling the conductor insulation would melt beyond the boundary zones. In contrast, with small cross sections it is possible that melting does not yet take place, even in the desired areas. Lastly, mandatory cooling takes place in step 38. Since a large amount of energy is introduced into the system, the line connection is very hot after the process and must be cooled down. This may take place actively, for example using compressed air, or passively via a holding time before further processing. In addition, cooling is advantageous, since otherwise, some materials would require finishing. Due to mechanical stress in the hot state, cracks may develop in the melt which result in leaks. When the process is complete, the line connection may be removed from the device in step 39.

LIST OF REFERENCE NUMERALS

[0051] 01contact point area [0052] 02line connection [0053] 03electrical line [0054] 04electrical conductor [0055] 05conductor insulation [0056] 06- [0057] 07heat shrink tube [0058] 08first area [0059] 09second area [0060] 10outer border area [0061] 11- [0062] 12electrical connector [0063] 13extension of the heat shrink tube [0064] 14terminal contact [0065] 20hot air feed duct [0066] 21heated air [0067] 22cooling air duct [0068] 23cool air [0069] 24inductor [0070] 30insertion of the line connection [0071] 31clamping of the line connection [0072] 32shrinkage and sealing process [0073] 33optional preheating [0074] 34induction heating [0075] 35heating of the heat shrink tube and hot-melt adhesive [0076] 36thorough heating of the heat shrink tube [0077] 37optional cooling [0078] 38cooling [0079] 39removal of the line connection