MOISTURE-PROTECTED ELECTRICAL CONNECTION

Abstract

The invention relates to a moisture-protected electrical connection between a flat conductor and an insulated cable with a different cross-section to this and a soldering point, wherein a stripped, exposed cable end is surrounded by a solder foot or a cable end sleeve at the soldering point and is in material contact with an end of the flat conductor, and also a protective body.

Claims

1. Moisture-protected electrical connection between a flat conductor (7) and an insulated cable (6) with a different cross-section to this and a soldering point, wherein a stripped, exposed cable end (5) is surrounded by a solder foot or a cable end sleeve at the soldering point and is in material contact with the end of the flat conductor (7), and also with a protective body, characterized in that the protective body consists of a sandwich arrangement, wherein an insulating, elastic mass of a first material is formed into a bead (1), surrounds the soldering point spaced over the surface and extends both to the soldering point upper side of the flat conductor and to its lower side and is extended up to a region (10) in which the insulation of the cable (6) and the flat conductor (7) no longer touch or lie on top of one another, wherein the bead (1) together with the space enclosed by it is enclosed by a second material (2) for the sandwich formation.

2. Moisture-protected electrical connection according to claim 1, characterized in that the first material has a lower hardness than the second material (2) in the operational state of the connection.

3. Moisture-protected electrical connection according to claim 1, characterized in that the bead (1) in the cable sheath section has a concave transition zone (8) facing the cable surface.

4. Moisture-protected electrical connection according to claim 1, characterized in that the bead (1) including the flat conductor (7) or the insulated cable (6) has a substantially circular or oval cross-sectional area.

5. Moisture-protected electrical connection according to claim 1, characterized in that the second material (2) is translucent or transparent.

6. Moisture-protected electrical connection according to claim 1, characterized in that the first material has a residual or permanent elasticity in the operational state of the connection.

Description

[0025] The invention shall be explained in more detail below based on an exemplary embodiment using figures.

[0026] In the figures:

[0027] FIG. 1 is an illustration in the form of a plan view of a moisture-protected electrical connection with a flexible connection cable on the one hand and a flat conductor with a different cross-section to this with soldering point connection area;

[0028] FIG. 2 is an illustration similar to FIG. 1, but without the second material enveloping the connection area with the solder joint area still completely exposed, not covered and surrounded only laterally by the bead (illustrated in section); and

[0029] FIG. 3 is a sectional illustration of the moisture-protected connection with the recognizable cross-sectional area of the bead.

[0030] The moisture-protected electrical connection according to the exemplary embodiment is based on a flat conductor 7, which has a soldering section 4.

[0031] In the region of the soldering section 4, an electrical connection is established between the stripped end 5 of an otherwise insulated cable 6.

[0032] The stripped end 5 of the cable 6 is surrounded by a solder foot or a ferrule or cable end sleeve 11 and is in material electrical contact with the section 4 in the soldering process.

[0033] The formation of a bead 1, as shown in FIG. 3, which surrounds the upper and lower side of the flat conductor 7 in the area around the solder joint and at a distance from it, is now essential for moisture protection.

[0034] The bead 1 is extended up to a region 10 in which the insulation of the cable 6 and the flat conductor 7 no longer touch or lie on top of one another.

[0035] In this region 10, the bead 1 envelops the insulating envelope of the cable 6 completely and sufficiently, forming a concave transition zone 8.

[0036] This eliminates the ingress of moisture in the direction of the solder joint region.

[0037] After a visual and, if necessary, electrical inspection of the solder joint, the bead 1 together with the space enclosed by it is enclosed by a second material for the sandwich formation, which is indicated in FIG. 1 with reference numeral 2.

[0038] This second material 2 can be translucent or transparent in order to enable a visual check of the solder joint or connection area even in the long run. A company logo, e.g. “FEW”, can also be attached.

[0039] For the material of the bead 1, which is shown as a pre-sealant in the form of a ring, a material was used which has the most satisfactory adhesion properties to the corresponding materials, such as the cable insulation, the solder and the film or flat conductor 7 used. The product Technomelt PA 678 Black, also known as Macromelt OM 678 produced by the company AG & Co. KGaA is preferably used here.

[0040] This product is a hot melt polyamide, which is thermoplastic and has a temperature resistance of up to 160 degrees.

[0041] The fully enclosing protective body from a second material 2, which is applied at a later time, preferably consists of a potting material Ultramid B3K.

[0042] This material, originating from BASF AG, ensures the required mechanical properties for the finished part. The material is also advantageous in terms of its low processing temperature and its low viscosity. Higher processing temperatures as well as higher viscosity lead to greater stress on the PI film adhesive, which is bonded to the copper conductor, and ultimately also to unnecessary stress in relation to the pre-sealant.

[0043] Surprisingly, it was observed that the pre-sealant was not undermined when the Ultramid material was used.

[0044] The Ultramid is a free-flowing, stabilizing and fast processing injection-moulding material.