阅读说明：本技术 用于连接和密封电气的部件的方法 (Method for connecting and sealing electrical components ) 是由 M.弗里德里希 M.多林 N.费雷拉 于 2020-08-17 设计创作，主要内容包括：本发明涉及一种用于连接和密封电气的部件与至少一条导线的方法以及相应地构造的组件。为此提供电气的部件、优选交通工具中的用于高压车载电网的汇流排和具有去除绝缘的端部的至少一条导线。将密封套筒推套到所述至少一条导线上并且所述密封套筒这样定位,使得所述密封套筒不会对电气的部件的注塑包封造成影响或者所述密封套筒本身不会一起被注塑包封。之后将电气的部件与至少一条导线连接。接着对组件进行注塑包封,其中,还构成注塑包封部与至少一条导线的绝缘部的重叠区域。之后将密封套筒移动至该重叠区域中。由于密封套筒具有比重叠区域中的注塑包封部更小的直径,因此在密封套筒、注塑包封部和至少一条导线的绝缘部之间构成挤压密封结构,从而不会有湿气和其它侵蚀性的介质渗入组件中。(The invention relates to a method for connecting and sealing an electrical component to at least one line and to a correspondingly designed assembly. For this purpose, electrical components, preferably busbars for a high-voltage onboard power supply in a vehicle, and at least one line having an end section with insulation removed are provided. The sealing sleeve is pushed onto the at least one conductor and is positioned in such a way that it does not interfere with the injection molding of the electrical components or that the sealing sleeve itself is not injection molded together. The electrical component is then connected to the at least one line. The component is then encapsulated by injection molding, wherein an overlap region of the injection molded part and the insulation of the at least one conductor is also formed. The sealing sleeve is then moved into this overlap region. Since the sealing sleeve has a smaller diameter than the encapsulation in the overlapping region, a compressive seal is formed between the sealing sleeve, the encapsulation and the insulation of the at least one line, so that no moisture or other aggressive media can penetrate into the assembly.)

1. A method for connecting and sealing an electrical component (30) encapsulated with a non-conductive material to at least one conductor (10), comprising at least the following steps:

providing at least one conductor (10) and a component (30) to be connected to the conductor, the conductor having an end portion with insulation removed in a connection region (12),

pushing the sealing sleeve (20) over the at least one conductor (10) in each case,

positioning the respective sealing sleeve (20) outside the connection region (12) together with at least one overlap region (14) to be realized of the injection-molded part (40) and the insulation of the at least one conductor (10),

connecting the component (30) to at least one line (10) in the connecting region (12),

injection-molding the component (30), the connecting region (12) and the corresponding overlap region (14) to be realized in a non-conductive material,

the press-fit sealing structures are produced by positioning the respective sealing sleeves (20) in the overlap region (14).

2. Method according to claim 1, characterized in that the press seal is formed by applying force and/or at least heating the sealing sleeve (20).

3. Method according to claim 1 or 2, characterized in that the at least one wire (10) is connected to the component (30) by means of ultrasonic welding or laser beam welding.

4. Method according to one of the preceding claims, characterized in that the injection-molding is carried out with a thermoplastic plastic.

5. Method according to one of the preceding claims, characterized in that the sealing sleeve (20) consists of a plastic or ceramic material.

6. Method according to one of the preceding claims, characterized in that the injection-molded part (40) consists of a fibre-reinforced structure and/or the sealing sleeve (20) consists of a fibre-reinforced structure.

7. Method according to one of the preceding claims, characterized in that the sealing sleeve (20) is positioned such that it surrounds the wire-side end of the overlap region (14).

8. Method according to one of the preceding claims, characterized in that the press seal is formed by at least one detent point (42) and/or the press seal is formed by at least one detent point (42).

9. Method according to one of the preceding claims, characterized in that the component (30) is a distributor for electrical energy, in particular in a high-voltage on-board electrical system of a vehicle, and/or the component (30) is an electrical consumer.

10. A sealed, non-conductive material injection-molded electrical component (30) which is connected to at least one conductor (10),

the component (30) is connected to the end of the at least one line (10) which is insulated in the connection region (12),

injection-molding the component (30), the connection region (12) of the at least one conductor (10) and the overlap region (14) of the at least one conductor (10) with a non-conductive material, wherein an insulation of the at least one conductor (10) is also injection-molded in the overlap region (14), and

in each case, a press-fit seal is formed in the overlap region (14) by means of a sealing sleeve (20).

Technical Field

The invention relates to a method for connecting and sealing an electrical component encapsulated by a non-conductive material to at least one conductor, and to an electrical component connected to at least one conductor, encapsulated and sealed.

Background

Electrical components, in particular for energy distribution in the high-voltage on-board electrical system of a vehicle, have to be increasingly smaller. Various solutions have been developed in the past to seal these electrical components against the effects of moisture and aggressive media in the vehicle. Said solutions mainly propose to envelope the components with a separate housing. To further seal, a sealing device is mounted at the cable end. However, this measure is time-consuming and requires a plurality of separate steps. Furthermore, due to the presence of vibrations and lateral forces in the vehicle and environmental conditions in which aggressive media such as water, brake fluid, fuel, salt, etc. act, the installed seals may loosen or quickly wear.

In a different embodiment, the electrical components arranged in the housing are filled with a non-conductive potting compound, which nevertheless serves as a seal. However, for this purpose, additional equipment for producing the cast component must be provided, and the formation of the usable component here also requires a plurality of separate steps.

More recent developments in the prior art suggest injection molding of the components. For example, the electrical components are inserted into an injection mold, where they are then encapsulated with a non-conductive, simultaneously hermetically acting material. However, if electrical components which are already connected to the electrical lines are to be encapsulated in this way, the problem arises that electrical lines, in particular for high-voltage vehicle electrical systems, are mostly insulated by silicone-coated casings and are injection-molded, for example, by polyamides which do not adhere to silicone or cannot be sealed with respect to silicone.

Disclosure of Invention

The object of the invention is to provide a method for insulating and effectively sealing an electrical component connected to at least one line.

The object of the invention is achieved by a method according to the invention and a component according to the invention.

In the method according to the invention for connecting and sealing an electrical component that is encapsulated in a non-conductive material and is to be connected to at least one line, at least the following steps are carried out:

providing at least one conductor and a component to be connected to the conductor, the conductor having an end portion with insulation removed (or with an insulation sheath stripped) in a connection region,

pushing the sealing sleeve over the at least one conductor,

positioning the respective sealing sleeve outside the connection region and at least one region of overlap (or overlap region) to be realized of the injection-molded part and the insulation of the at least one line,

connecting the component to at least one line in the connecting region,

injection molding the component, the connecting region and the corresponding overlap region to be realized in a non-conductive material,

the press sealing arrangement (Pressdichtung) is produced by positioning the respective sealing sleeve in the overlap region.

Electrical components in the sense of the present invention are components or assemblies into and/or out of which an electrical current is conducted. The electrical component can be, in particular, a distributor for electrical energy or current or, for example, an electrical consumer (or a power consumer) which contains a lighting device and is operated by current. The term "component" may be used synonymously with "electrical component" in the following.

It is particularly preferred that the electrical component is a distributor for electrical energy in a high-voltage on-board electrical system in a vehicle. Such a distributor can preferably be realized in the form of a so-called Busbar or Busbar (Busbar). Since the bus bars are connected to all the input and output lines, the bus bars or bus bars are generally understood in the art as conductor arrangements which act as central distributors of electrical energy. The busbars are typically uninsulated. According to the invention, the insulation is carried out in one of the subsequent steps of the disclosed method.

The on-board electrical system contains all electrical components in the vehicle and is used for the power supply and the communication of information between the components of the vehicle and the control device. High-voltage vehicle electrical systems describe vehicle electrical systems which are operated with an alternating voltage of more than 30V up to 1KV or with a direct voltage of more than 60V up to 1.5 KV.

In the method according to the invention, the electrical component is to be connected to at least one line. A conductor is understood here to mean an electrical line, i.e. a device for transmitting electrical current and information. The wire may be made up of one or more individual conductors, also known as litz wires, and is usually insulated outwards. Different plastics, also including silicone, are generally used as insulating materials, which surround the individual conductors and insulate them from one another.

In order to carry out the method according to the invention, at least one line to be connected to the electrical component must be insulated in the region in which the connection is to be carried out. I.e. where the insulating layer should be removed. This region is typically one of the ends of the respective wire. In the context of the method, the region from which the insulation is removed is to be referred to below as the connection region.

At least one conductor with an end section with insulation removed and an electrical component which is to be connected to the at least one conductor are now provided for carrying out the subsequent steps. The sealing sleeves are respectively pushed and sleeved on at least one wire. The sealing sleeve is a substantially cylindrical body with a bore or through hole along a longitudinal axis which is guided through the center of the substantially circular base surface of the cylindrical body. As long as bores or through-holes are formed in the sealing sleeve, any other shape can naturally also be selected for the sealing sleeve.

The inner diameter of the sealing sleeve should be adapted to the intended dimensions of the injection molding of the electrical components and the lines to be connected in a subsequent step. The inner diameter is selected such that the sealing sleeve can be pushed loosely onto the respective line, but is also selected such that a press-fit sealing structure can then be realized as will still be explained.

The sealing sleeve must be positioned outside the connection area. In addition, in the method according to the invention, an overlap region of the encapsulation of the electrical component and the insulation of the at least one electrical line should be realized. In this region, the encapsulation should cover the insulation of the at least one line at least in sections. I.e. the sealing sleeve, must also be positioned sufficiently far away from the electrical components on the line in order to be able to form this overlap region. The sealing sleeve must therefore be positioned at least with the dimensions of the connecting region and the overlap region away from the electrical component.

The component is now connected to the at least one line in the connection region of the at least one line. As will be explained in more detail elsewhere, the connection can be effected in a friction-fit, material-bonded and/or form-fitting manner.

If all the required wires are connected to the electrical component, the electrical component is encapsulated by injection molding with a non-conductive material, i.e. with a material that does not conduct current, which thus serves as an insulation of the electrical component. The envelope or the injection-molded envelope is produced by an injection molding process, preferably an injection molding process.

In an injection molding process, a component having at least one connected conductor is placed in an injection mold, and the injection mold is filled with a non-conductive material. The thickness of the envelope is defined by the injection mold. In addition to the electrical components, the injection molding or the envelope should also cover the connection region of the at least one line and the overlap region of the at least one line.

If the encapsulation has already been carried out and cured, the pinch seal is formed in the overlap region by means of the sealing sleeve by moving the sealing sleeve into the overlap region. A press-fit sealing arrangement is achieved if the inner diameter of the sealing sleeve is at least slightly smaller than the outer diameter of the at least one line together with the injection molding compound in the overlap region. By moving the sealing sleeve into the overlap region, the non-conductive material of the insulating part and the encapsulation part is pressed through the sealing sleeve and sealed against one another in the overlap region.

The steps described above are carried out for each conductor connected to the electrical component, except that the electrical component and the at least one conductor connected to the electrical component are encapsulated. In this case, the steps can be carried out either individually for each line or else separately for each line to be connected, and then the next step can be carried out.

The method according to the invention is used to connect an electrical component to at least one line, is surrounded in its entirety by an insulating material as far as the overlapping region of the at least one line, and is sealed and protected against the ingress of water, fuel, brake fluid and other aggressive media by means of a sealing sleeve by pressing a sealing structure. The method is easy to implement without incurring significant additional expense.

In a first preferred embodiment of the invention, it is provided that the press-fit sealing arrangement is formed by applying force and/or at least heating the sealing sleeve. Since the inner diameter of the sealing sleeve is at least slightly smaller than the outer diameter of the overlapping region of the at least one injection-molded conductor, a displacement into the overlapping region can be made easier by applying a force on the sealing sleeve. The sealing sleeve can be pressed in the direction of the overlap region with pressure and into the desired target position, or can be moved into the overlap region by applying a tensile force. Alternatively or additionally, the sealing sleeve can be heated, so that it expands and can therefore be moved more easily into the desired position in the overlap region. The temperature at which the sealing sleeve is heated should be selected such that the sealing sleeve itself or the non-conductive material of the injection molding does not have an adverse effect on account of the elevated temperature.

The connection of the at least one line to the electrical component is effected in a friction-fit, material-bonded and/or form-fitting manner. In a preferred embodiment, the at least one line is connected to the electrical component by ultrasonic welding or laser welding.

Ultrasonic welding belongs to the category of friction welding. The joining of the components to be joined is effected here by high-frequency mechanical vibrations which, due to molecular and boundary surface friction, lead to a temperature increase between the components.

Laser beam welding, also known as laser welding, is carried out by means of a laser beam. Laser welding is primarily suitable for welding components that must be joined with high welding speeds, narrow and elongated weld shapes, and less thermal warping.

The connection of the at least one line to the electrical component can alternatively also be realized as a plug connection.

In a further preferred embodiment, it is provided that the encapsulation is realized by a thermoplastic, in particular polyamide 12. Thermoplastics are plastics which can be deformed in a defined temperature range. The deformation is a reversible process as long as the material is not overheated and a so-called thermal decomposition of the material takes place here. Furthermore, thermoplastics are weldable. It is further preferred to use polyamides, since they have very good strength and toughness as well as processability and chemical stability.

Polyamide 12 may be used, for example, as a non-conductive material for injection molding the component and the at least one conductor connected to the component. Polyamide 12 (also abbreviated as PA12) is a partially crystalline thermoplastic having the lowest water absorption of all polyamides. Polyamide 12 is distinguished by high toughness and good chemical stability and resistance to thermal deformation up to 50 ℃ and, owing to its properties, is particularly suitable for use in moist environments or when high dimensional stability is required.

In a further preferred embodiment, the sealing sleeve is made of a plastic or ceramic material. Plastics are suitable because of their chemical stability, flexible shaping and at the same time being light. Ceramic sealing sleeves are made of or made of so-called industrial ceramics and are advantageously suitable for their high hardness, chemical stability, wear resistance and corrosion resistance.

Both the sealing sleeve and the injection-molded part may be formed from a fiber-reinforced structure. In this case, fibers are added to the base material of the non-conductive material of the sealing sleeve or the injection molding, respectively, in order to form a composite material with improved properties. The fibers also increase the strength of the material surrounding the fibers. The fibers may be, for example, glass fibers suitable for the respective use. However, ceramic, carbon or nylon fibers may also be used. In any case, the properties of the fibers should be adapted in harmony with the properties of the material surrounding the fibers.

In a further preferred embodiment of the method according to the invention, the sealing sleeve is positioned in such a way that it surrounds the conductor-side end of the overlap region. The conductor-side end of the overlap region is the region of the at least one conductor in which the overlap of the non-conductive material with the insulation of the at least one conductor ends. The region is in particular the terminal edge of the injection-molded part. In this embodiment of the method, it is provided that the edge or the conductor-side end of the overlap region is surrounded by a sealing sleeve. That is to say the sealing sleeve should be positioned such that it covers the conductor-side end of the overlap region, i.e. the conductor-side end of the overlap region is covered by the sealing sleeve. The sealing sleeve thus provides additional protection in the overlap region for the edge region of the conductor-side end of the injection molded part against the penetration of aggressive media and also against mechanical damage.

In a further preferred embodiment, it is provided that the press-fit seal is formed by at least one latching point (or latching point) and/or that the press-fit seal is formed by at least one latching point. In the sense of the present invention, this is to be understood as meaning a form-fitting connection between the sealing sleeve and the encapsulation by forming at least one latching point in order to lock the position of the sealing sleeve in the use state in which vibrations and forces act from the outside on the encapsulated component. For this purpose, projections or indentations can be provided in the sealing sleeve, i.e. in the through-hole or bore, and corresponding recesses or indentations can be formed in the overlapping region of the injection-molded part. If the sealing sleeve is moved into the overlap region, the projections and the corresponding recesses engage with one another and thus form a form-fitting connection which locks the position of the sealing sleeve.

However, it is also possible within the scope of the invention to form the projections or the evaginations in the overlapping region of the injection molding and to form corresponding recesses or indentations in the interior of the sealing sleeve, i.e. along the through-holes or bores in the sealing sleeve. The recess may also be a split in the sealing sleeve or a hole in the sealing sleeve.

The projections or the evaginations can each be point-shaped or linear, independently of the element on which they are formed, in order to form at least one latching point. More than one latching point can be formed, and the individual projections or the evaginations can have the same or different shapes. However, the recess or indentation on the counter element should correspond as far as possible to the projection or the evagination in order to form a reliable holding.

According to the invention, a sealed electrical component is also claimed, which is encapsulated by a non-conductive material and is connected to at least one line, wherein the component is connected to the end of the at least one line, which end is insulated in the connecting region. The component, the connecting region and the overlap region of the at least one line are encapsulated by a non-conductive material, wherein the insulation of the at least one line is also encapsulated in the overlap region. In each case a press-fit sealing structure is formed in the overlap region by means of a sealing sleeve.

The method according to the invention and the injection-molded electrical component according to the invention provide a reliable seal of the electrical component connected to the electrical line, which can be produced simply and cost-effectively. A very small design can be achieved in this case.

The various embodiments of the invention mentioned in the present application can advantageously be combined with one another as long as they are not specified otherwise in individual cases.

The invention is elucidated below in the examples with reference to the accompanying drawings. In the drawings:

fig. 1a to 1d show an exemplary sequence of the method according to the invention in a schematic view, and

fig. 2a to 2b show a detail of fig. 1.

Fig. 1a to 1d show exemplary sequences for carrying out the method according to the invention in schematic views. For reasons of intuition, all components are no longer individually labeled in fig. 1b to 1 d. The reference lines show the mutual orientation of the individual elements and make the correspondence easier.

By means of the method according to the invention, for example, an electrical component 30 is connected to the exemplary three lines 10, and the component 30 is encapsulated by a non-conductive material and the lines 10 are encapsulated in regions in order to insulate the assembly. In the exemplary embodiment, electrical component 30 is a bus bar, by means of which electrical energy is distributed to a high-voltage on-board electrical system of the vehicle.

As can be seen in fig. 1a, three wires 10 are provided with insulation removed in the connection area 12. Fig. 1b shows that the sealing sleeve 20 is pushed onto each conductor 10 and, as can be seen from the overall view of fig. 1, is removed from the connection region 12 and the overlap region 14 to be realized. In each overlap region 14, the encapsulation 40 which is then realized should cover the insulation of the line 10 at least in sections, with the aid of which encapsulation 40 the busbar 30 is insulated. In fig. 1b, the busbar 30 is connected to each of the three lines 10 in its connecting region 12 by means of ultrasonic welding.

As can be seen from fig. 1c, the injection molding 40 of the bus bar 30 is realized with a thermoplastic, for example polyamide 12. This is achieved in an intermediate step by means of an injection molding process. The fibers may also already be embedded in the plastic to reinforce the injection molded part 40. During the encapsulation, an overlap region 14 is also realized on each conductor 10, in which overlap region the polyamide 12 also envelops the conductor 10 in each case.

Then, the sealing sleeves 20 are respectively moved into the overlapping regions 14 in the directions indicated by the arrows by the pressing force. The sealing sleeve 20 is made of plastic, so that it is resistant (or stable) to aggressive media in the engine compartment of the vehicle. The sealing sleeve 20 is now positioned in such a way that the respective conductor-side end of the injection-molded part 40, i.e. the edge formed there, is surrounded and covered by the sealing sleeve 20.

Fig. 2a is directed to fig. 1c and shows a detail with a circle, which is shown enlarged in fig. 2 b. Fig. 2b shows that the two latching points 42 are formed in the overlap region 14 in the form of projections for which two corresponding recesses 22 are provided in the sealing sleeve 20, so that, when the sealing sleeve 20 is pushed over, a positive-locking connection is produced between the respective sealing sleeve 20 and the encapsulation 40, which positive-locking connection can also lock the position of the sealing sleeve 20 under vehicle-specific action.

Since the inner diameter of the sealing sleeve 20 is smaller than the outer diameter of the encapsulation 40 in the overlap region 14, the sealing arrangement is compressed by the action of the push-on sealing sleeve 20, i.e. a compression is formed between the sealing sleeve 20, the encapsulation 40 in the overlap region 14 and the insulation of the line 10, which compression seals the connection.

As a result, an assembly is formed in which the busbar 30 is connected to the three wires 10 and is sealed against penetration of water, fuel, brake fluid or other media. By using the method according to the invention, the assembly can be constructed very compactly and compactly.

List of reference numerals

10 wire

12-wire connection region

14 overlap region

20 sealing sleeve

22 recess for receiving a latching point

30 electrical component

40 injection molding of the envelope part

42 latching location