TANK INCLUDING A CONNECTOR AND METHOD FOR CONNECTING AN ELECTRICAL DEVICE IN A TANK

Abstract

The invention relates to a tank (300) comprising an electrical device (400) attached to a first connector (100), said first connector being adapted for being coupled to a second connector, said first connector comprising a first plastic part (110) and at least one first electrically conductive contact element (121, 122), said at least one first electrically conductive contact element being electrically connected with said electrical device, said second connector comprising a second plastic part and at least one second electrically conductive contact element, said at least one second electrically conductive contact element being configured for being coupled with said at least one first electrically conductive contact element, wherein said first plastic part is adhered along a closed curve extending around the at least one first electrically conductive contact element to a plastic portion inside the tank.

Claims

1: A tank, comprising: an electrical device attached to a first connector, said first connector being configured for being coupled to a second connector, said first connector comprising a first plastic part and at least one first electrically conductive contact element, said at least one first electrically conductive contact element being electrically connected with said electrical device, said second connector comprising a second plastic part and at least one second electrically conductive contact element, said at least one second electrically conductive contact element being configured for being coupled with said at least one first electrically conductive contact element, wherein said first plastic part is welded along an outer circumferential edge, which is a closed curve extending around the at least one first electrically conductive contact element, to a plastic portion inside the tank, wherein said second plastic part comprises an outer circumferential edge welded to an outer side of said tank surrounding the connector opening or to the outer circumferential edge of the first plastic part, the second plastic part of the second connector being the plastic portion inside the tank.

2: The tank of claim 1, wherein the first plastic part is welded along a closed curve to the second plastic part of the second connector, around the at least one first and second electrically conductive contact element.

3: The tank of claim 2, wherein said first connector is coupled to said second connector inside said tank, and said first and second connectors are located entirely within the tank.

4: The tank of claim 1, wherein the electrical device comprises at least one connection cable, wherein the at least one connection cable comprises an end which is sealingly integrated in the first plastic part, and wherein the at least one first electrically conductive contact element is electrically connected to at least one connection wire of the at least one connection cable.

5: The tank of claim 1, wherein the electrical device has two connection cables, and wherein the first connector comprises two electrically conductive contact elements connected to said two connection cables inside the first plastic part.

6: The tank of claim 1, wherein said at least one first or second electrically conductive contact element comprises at least one connector pin, and wherein said at least one second or first electrically conductive contact element comprises at least one contact bus dimensioned for receiving said at least one connector pin.

7: The tank of claim 1, wherein the first plastic part comprises a first positioning element between the at least one first electrically conductive contact element and the closed curve, and the second plastic part comprises a second positioning element configured to cooperate with said first positioning element such that the positioning of the second connector is guided by the first and second positioning elements.

8: A method for connecting an electrical device in a tank, comprising: providing said electrical device with a first connector, said first connector comprising a first plastic part and at least one first electrically conductive contact element electrically connected with said electrical device; and assembling the tank such that said first plastic part is adhered along a closed curve to a plastic portion inside the tank and such that a second connector is coupled with said first connector, wherein said second connector comprises a second plastic part and at least one second electrically conductive contact element, said at least one second electrically conductive contact element being coupled with said at least one first electrically conductive contact element.

9: The method of claim 8, wherein the assembling is done such that said first plastic part is welded along an outer circumferential edge, which is a closed curve extending around the at least one first electrically conductive contact element, to the plastic portion inside the tank.

10: The method of claim 9, wherein said second plastic part comprises an outer circumferential edge welded to an outer side of said tank surrounding the connector opening or to the outer circumferential edge of the first plastic part, the second plastic part of the second connector being the plastic portion inside the tank.

11: The method of claim 8, wherein the first plastic connector is made by overmoulding a connection cable with the plastic material, and by connecting the at least one first electrically conductive contact element to a connection wire of the connection cable.

12: The method of claim 8, wherein the assembling of the tank comprises: adhering the first plastic part along a closed curve to an inner side of a first tank shell, adhering the first tank shell to a second tank shell such that a tank enclosing the electrical device is formed, and coupling the second connector to the first connector.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0039] The accompanying drawings are used to illustrate presently preferred non-limiting exemplary embodiments of devices of the present invention. The above and other advantages of the features and objects of the invention will become more apparent and the invention will be better understood from the following detailed description when read in conjunction with the accompanying drawings, in which:

[0040] FIG. 1 illustrates schematically a cross-section of an exemplary embodiment of a tank comprising a first connector;

[0041] FIG. 2 illustrates schematically a cross-section of the first connector of FIG. 1 coupled to a second connector;

[0042] FIG. 3 illustrates schematically a cross-section of an exemplary embodiment of a tank comprising a mounting flange with a first connector coupled to a second connector;

[0043] FIG. 4 illustrates schematically a cross-section of an exemplary embodiment of a tank comprising two heaters and a first connector coupled to a second connector, wherein both the first connector and the second connector are located inside the tank;

[0044] FIG. 5 illustrates schematically a perspective view of an exemplary embodiment of a first connector and a second connector which can be coupled to each other;

[0045] FIG. 6 illustrates schematically a perspective view of another exemplary embodiment of a first connector and a second connector which can be coupled to each other;

[0046] FIG. 7 illustrates schematically a cross-section of an exemplary embodiment of a tank comprising a first connector coupled to a second connector integrated in a frame; and

[0047] FIGS. 8A-D illustrate schematically top views of a number of possible closed curves.

DESCRIPTION OF EMBODIMENTS

[0048] FIG. 1 illustrates an exemplary embodiment of a tank 300 comprising a first connector 100 attached to an electrical device 400, e.g. a heater, a pump, a sensor, etc. The first connector 100 comprises a plastic part 110 and two electrically conductive contact elements 121, 122 protruding out of a coupling side 120 of the plastic part 110. The first electrically conductive contact elements 121, 122 are electrically connected with the electrical device 400 via cables 131, 132 which are integrated in the plastic part 110 of first connector 100, wherein the cables 131, 132 are electrically connected to the first electrically conductive contact elements 121, 122, respectively. First connector 100 is adapted to be coupled with a second connector 200, see FIG. 2. The second connector 200 comprises a second plastic part 210 and two second electrically conductive contact elements 221, 222 protruding out of a coupling side 220 of the second connector 200. The two second electrically conductive contact elements 221, 222 are configured for being coupled with the first electrically conductive contact elements 121, 122, respectively.

[0049] The first plastic part 110 is welded along a closed curve 150, e.g. along a ring surface, to a plastic portion inside the tank 300, here an inner side 350 of the tank surrounding a connector opening 330 in the tank 300. The closed curve 150 extends around, i.e. surrounds or includes, the first electrically conductive contact elements 121, 122. In a typical embodiment, the tank 300 comprises a first shell 310 and a second shell 320 which are welded along a circumferential flange 311, 321 to form the tank 300. The welding along the closed curve 150 of the first connector 100 may be performed before the first and second shells 310, 320 of tank 300 are welded. In an exemplary embodiment, the first connector 100 is welded to the inner side 350 of the tank by hot plate welding or by laser welding from the outside of the tank 300. In the latter case the tank is preferably manufactured from a material which is transparent for the laser radiation, whilst the first plastic part 110 is preferably manufactured from a plastic material configured to absorb heat, e.g. a black plastic material.

[0050] The first plastic part 110 is welded such that the electrically conductive contact elements 121, 122, protruding outward of the first plastic part 110, are accessible from the outside of the tank. More in particular, the first and second electrically conductive contact elements 121, 122 are protruding outwardly of the first plastic part 110 at a coupling side 120 of the first connector 100. At the other cable side 130 of the first connector 100, first and second cables 131, 132 power the electrical device 400. The connection cables 131, 132 have an end which is sealingly integrated in the first plastic part 110, and the two first electrically conductive contact elements 121, 122 are electrically connected inside the first plastic part 110 to the two connection wires of the two connection cables 131, 132.

[0051] The two electrical cables 131, 132 may have a plastic sheath made of a thermoplastic polymer material that is compatible with the thermoplastic material of the plastic part 110 in the sense that polymer entanglements are created at the interface of the sheath and the plastic material. The sheath may be made e.g. of a polyamide material, and the thermoplastic plastic material may be e.g. a compatible poly-ethylene material optionally comprising a compound for increasing the polarity (e.g. PE grafted with maleic anhydride, PRIEX), a polyamide material or a compatible polypropylene material. A polyethylene, grafted with an extra high content of maleic anhydride has the advantage that the grafted maleic anhydride introduces polarity to the polymer achieving compatibility between polyolefins and more polar materials or polymers like EVOH or Polyamide. More generally, the skilled person understands that many compatible materials exist for the sheath and the plastic part. There exist tables showing plastic welding compatibility (see e.g. www.lpkfusa.com/lq from the laser welding company LPFK). Such welding compatibility tables also provide a good indication of the compatibility of two materials (sheath material and plastic material of part to be formed) that are being overmoulded.

[0052] Further, the first plastic part 110 of the first connector 100 comprises a first positioning element 140 at the coupling side 120, and the second plastic part 210 of the second connector 200 has a corresponding positioning element 240 at the coupling side 220. These first and second positioning elements 140, 240 may be e.g. cylindrical parts extending around the first and second contact elements 121, 122; 221, 222, and configured to cooperate in a telescopic manner. End parts of the positioning elements 140, 240 may be chamfered to further facilitate the guiding of the positioning elements 140, 240 with respect to each other.

[0053] Optionally, the second plastic portion 210 may be welded along a closed curve 250 to an outer side 360 of the tank 300. In that manner, the electrically conductive coupling portions 121, 122; 221, 222 will be sealed from the outside avoiding e.g. moist penetration between the coupling sides 120, 220 of the first and second connector 100, 200.

[0054] FIG. 3 illustrates schematically a second exemplary embodiment of the invention. In this embodiment, the tank 300 has a flange opening 340 which is closed by a mounting flange 500. In this embodiment, the first connector 100 has a first plastic part 110 which is welded along a closed curve 150 to the inner side 550 of the flange 500, around a connector opening 530 in the mounting flange 500. In other words, the first connector 100 is welded to the immersed side of the mounting flange 500. The first electrically conductive contact elements 121, 122 protrude outwardly of a coupling side 120 of the first connector 100, through the connector opening 530 in the mounting flange 500. The first connector 100 may be identical to the first connector 100 of the first exemplary embodiment of FIGS. 1 and 2, and may be connected in a similar manner to an electrical device 400. The second connector 200 is similar to the connector 200 of FIG. 2, with this difference that the second plastic part 210 is not welded to the outward side 560 of the flange 500. However, in an alternative embodiment, the second connector 200 may be similar to the second connector 200 of FIG. 2, and may be welded to the outer side 560 of the mounting flange 500. In yet another non-illustrated embodiment, there may be provided a cover over the second connector 200. Also, the second connector 200 may be part of an electronic unit mounted outside of the tank 300, e.g. on the outer side 560 of the mounting flange 500.

[0055] In a further developed embodiment shown in FIG. 7, the second connector 200 is integrated in a frame 800 attached to a cover 900. More in particular the second plastic part 210 of second connector 200 may be an integrated part of frame 800. Frame 800 may be connected to cover 900 by any type of suitable means, e.g. a snap-fit connection. A number of components 801, 802, 803, e.g. electronic components such as sensor or control parts, may be attached to the frame 800 and/or to the cover 900. Further, there may be provided a third connector 910 at a side wall of the cover 900 connected directly or indirectly to the second connector 200. In this embodiment the first connector 100 may be welded to an inner side 350 of a tank wall as in the embodiment of FIG. 1 or may be welded to an inner side 550 of a mounting flange, as in the embodiment of FIG. 3.

[0056] FIG. 4 illustrates schematically a third exemplary embodiment of the invention. In this embodiment, the tank 300 comprises two heaters 400, 600. A first connector is connected to the first heater 400 in the same manner as described above for electrical device 400. The second connector 200 is similar to the second connector of FIG. 2. However, in the embodiment of FIG. 4, both the first and the second connector 100, 200 are located entirely within the tank 300, and an outer circumferential edge 150 of plastic part 110 of the first connector 100 is welded to an outer circumferential part 250 of second plastic part 210 of the second connector 200. The cables 231, 232 provided at the cable side 230 of the second connector 200 are an integral part of the second heater 600. In that way, the first and the second heater may be connected in series inside the tank. The connecting cables 231, 232 may be brought outside of the tank via any suitable cable connection piece 700. Also, there may be provided instead of connection piece 700, a further first and second connector 100, 200, as in the embodiment of FIGS. 1 and 2 or FIG. 3. In other words, there may be provided a first connector 100 coupled to a second connector 200 entirely within the tank, as well as a first connector 100 welded to an inner side of the tank around a connector opening in the tank.

[0057] In other embodiments of the invention, there may be provided two heaters connected in parallel in the tank. This may be achieved e.g. by using the first and second connector 100, 200 of FIG. 6. The first connector 100 of FIG. 6 may be welded to an inner side of the tank, wherein connecting pins 121, 122 protrude outwardly of the tank. In this embodiment, the first connector 100 comprises four wire end parts of cables 131, 132, 131, 132. A first wire 131 e.g. connected to the first heater, and a first wire 131 e.g. connected to the second heater are both connected to a first contact pin 121. Similarly, a second wire 132 e.g. connected to the first heater, and a second wire 132 e.g. connected to the second heater are both connected to a second contact pin 122. In that way, a first and second heater may be fed in parallel. Of course it is also possible to provide two first connectors 100, and two second connectors 200 in order to connect a first heater independently of a second heater.

[0058] FIG. 5 illustrates a perspective view of an exemplary embodiment of a first and second connector. In this embodiment, the first plastic part 110 of the first connector 100 is shaped with a plurality of cylindrical parts, and the second connector 200 is shaped correspondingly with a plurality of cylindrical parts. The skilled person understands that the invention is not limited to connectors with a cylindrical shape, and that other shapes are equally possible, see e.g. the embodiment of FIG. 6. The various components of the first and second connector 100, 200 have been discussed above in the various embodiments, and are not repeated.

[0059] The closed curve 150 may have various shapes as illustrated in FIGS. 8A-8D. In a first exemplary embodiment the closed curve 150 is part of a ring shaped surface surrounding two electrically conductive contact elements 121, 122, as in FIG. 1. In a first exemplary embodiment the closed curve 150 is part of a triangular shaped surface surrounding three electrically conductive contact elements 121, 122, 123. In a third exemplary embodiment the closed curve 150 is a square surrounding one electrically conductive contact element 121. In a fourth exemplary embodiment the closed curve 150 is an oval surrounding six electrically conductive contact elements 121, 122, 123, 124, 125, 126.

[0060] Embodiments of the method of the invention allow obtaining a sealed interface for an electrical appliance arranged in a tank, e.g. in a urea tank, a diesel tank, a fuel tank, etc.

[0061] Whilst the principles of the invention have been set out above in connection with specific embodiments, it is to be understood that this description is merely made by way of example and not as a limitation of the scope of protection which is determined by the appended claims.