Arrangement for sealing the connection point of electrical lines

Abstract

An arrangement (20) for covering connecting points of electrical lines (2a-2c) in a moisture tight manner is indicated. The electrical conductors (3a-3d) of at least one first electrical line (1) are connected to the electrical conductors (4a-4f) with at least two further electrical lines (2a-2c). The connecting point is surrounded by a prefabricated housing (10) consisting of a mechanically stable synthetic material. The interior of the housing (10) is completely enclosed by a sealing material produced by injection molding which extends to both sides of the housing (10) up to the lines protruding beyond the housing (1, 2a-2c).

Claims

1. Method of manufacture of a cover for a moisture tight covering of a connection point of electrical lines, where the electrical conductors of at least one first electrical line is connected with the electrical conductors of at least two further electrical lines, said method comprising the steps of: surrounding the connection point with a prefabricated housing made of mechanically stable synthetic material, wherein the edges of the openings of the housing have sealing contours which are covered in a completely media tight manner by the injection molding material, and completely filling the interior of the housing by a sealing material produced by injection molding which extends on both sides of the housing over the lines protruding into the housing, wherein the injection molding material that protrudes beyond openings of the housing seals the openings in a media tight manner; and completely surrounding edges of openings of the housing through which the electrical lines pass in from the outside, sealing the openings in a media tight manner.

2. The method as claimed in claim 1, wherein the prefabricated housing is made from the group consisting of polyamide, thermoplastic polyurethane and polyethylene terephthalate.

3. Method according to claim 1, wherein the electrical conductors of the at least one first electrical line are connected by clamping connectors with the electrical conductors of the at least two further electrical lines.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the subject of the invention are illustrated in the drawings. In the drawings:

(2) FIG. 1 schematically illustrates an example of connected strands of an electric distributor in accordance with an embodiment of the arrangement according to the invention,

(3) FIG. 2 shows the prefabricated housing of the invention in accordance with an embodiment in a perspective view,

(4) FIG. 3 shows the arrangement according to a method step according to the invention in a top view, and

(5) FIG. 4 shows the arrangement according another method step according to the invention in a perspective view.

(6) In the drawings, equal method steps refer to equal technical features.

DETAILED DESCRIPTION

(7) In the following, the invention will be explained with the aid of an electric distributor as it can be used in a motor vehicle. The electric distributor is further representative as an example of all other possible arrangements of moisture tight coverings of the electrical connections.

(8) FIG. 1 shows a schematic example of a not yet sealed electric distributor. The strands 3a-3d of a first conductor 1 are distributed over the strands 4a-4f of 3 further electrical conductors, 2a-2c. In this example, the strands 3a-3d of the first conductor 1 with the strands 4a, 4b of the second conductor 2a and the strands 3c, 3d with the strands 4c, 4d of a third conductor 2b are connected. A fourth conductor 2c serves connect an electrical component 6, for example a passive electrical component such as a diode or a resistor by means of conductors, 4e-4g.

(9) The strands are connected to electrical conductors provided with insulation which can, for example, consist of copper or aluminum or an alloy. The ends of the electrical conductors from which the insulation has been removed and subsequently each are connected with a connector 5a-5d, for example an insulated clamp connector. Connectors that have not come in contact with conductors can also be uninsulated crimp connectors. In the illustrated example, the electrical component is connected by means of two connectors 5e, 5f with the conductors 4e, 4g.

(10) FIG. 2 shows an embodiment of a housing 10 for an electrical distributor. The housing 10 consists of mechanically stable plastic material. This insulating material is, for example, polyamide thermoplastic polyurethane or polyethylene terephthalate. The housing 10 has two openings 11, 12 for the passing through of the conductor 1 on the one hand and the further conductors, 2a-2c on the other hand. The housing 10 serves for covering the connecting point between the conductors and so that all the conducting points between the individual electrical conductors of the distributor.

(11) For manufacturing the electrical distributors, for example, the housing 10 is pushed over the first conductor 1 before the conductors are connected with each other. Subsequently, as illustrated in FIG. 1, the ends of all the conductors 1, 2a-2c connected to each other and the housing 10 are pushed over the connecting points. The result of the last step is illustrated in FIG. 3.

(12) In FIG. 4 an embodiment of a completed distributor 20 is illustrated. After the housing 10 is pushed over all the connecting points, the housing 10 with the continuous conductors is placed in an injection molding tool. The housing 10 is completely covered with injection molding material. As a result the connecting points between the individual conductors are entirely surrounded by injection molding material and thus are sealed media tight. In the illustrated example, the hardened injection molding material protrudes beyond the housing 10 and forms at the edges of the housing openings 11, 12 sealing elements 15a, 15b whereby the passage opening of conductors 1, 2a-2c are completely sealed through the openings 11, 12, completely sealed. The edges of the openings 11, 12 of the housing 10 are included in the injection molding process. The resulting shape of the injection molding material will be determined by the pre-pressed shape of the injection molding machine used.

(13) To increase the strength of the connection between the injection molding material and the housing 10, especially on the openings 11, 12, they preferably have sealing contours 13, 14. These sealing contours can, for example, lamellar formed, as illustrated in FIGS. 2 and 4. By use of the sealing contours 13, 14 it is ensured that during the injection molding process the injection molding material spreads out within the sealing contours 13, 14 and is securely anchored after the cooling process. The density with respect to media of the distributor 20 as well as the strength would be further increased. The sealing contours 13, 14, which are or constitute the surfaces of the edges, can take other suitable shapes or forms. Depending on the housing and the injection molding material, the surfaces of the edges can however remain unstructured to achieve a good strength between the injection molding material and the housing 10.

(14) The prefabricated housing 10 is structured in such a way that the size of the openings 11, 12 matches the number of conductors extending therethrough. The matches are a result of the application of the injection molding material. In this way it is possible to use prefabricated housings for a plurality of possible combinations of numbers of conductors. It is therefore possible to use the same housings for a multitude of different distributors.