WO2007036369A1

WO2007036369A1 - Method for producing self-sealing sections in conductor assemblies, in particular in vehicle electric systems and multi-core conductor assembly

Info

Publication number: WO2007036369A1
Application number: PCT/EP2006/009488
Authority: WO
Inventors: Gert Mauss; Wolfgang Nauditt
Original assignee: Gert Mauss; Wolfgang Nauditt
Priority date: 2005-09-29
Filing date: 2006-09-29
Publication date: 2007-04-05
Also published as: DE102005046771A1

Abstract

The invention relates to a method for producing vehicle electric systems, whose individual cores are automatically coated prior to completion of the vehicle electric system at least at one predefined point with a predefined quantity of a superabsorbent polymer. In the completed vehicle electric system, the polymer coatings lie at corresponding locations and form a self-sealing, water-repellent system in the presence of any moisture. Orifices and partitions of sub-divided and sealed sleeves are sealed with the aid of a superabsorbent polymer. Said superabsorbent polymers can also be used to coat the interior of control boxes and other housings to protect against condensation and act as emergency seals.

Description

Applicants: Gert Mauss and Wolfgang Nauditt

Our sign: PCT44740GKkor

Date: September 29, 2006

Method for producing self-sealing sections in line arrangements, in particular in on-board networks, as well as multi-wire line arrangement

The invention relates to a method for producing self-sealing sections in line arrangements, in particular in on-board networks, as well as a multi-wire line arrangement.

Such a method is already known from WO 96/16415. This paper deals with the problem of using multi-core vehicle electrical systems used in agricultural, water and aircraft construction to protect against the ingress of moisture (water) and crawling on the surfaces of the individual wires forming the vehicle electrical system.

The danger that moisture, such as condensation or water spray, creeps along the surfaces of the individual cores or on the surfaces of individual cores, and comes to the wire ends to blank electrical conductors or connectors, exists in particular in the range of passages through partitions, such as a passage by a motor compartment and the passenger compartment of a motor vehicle from each other separating wall, but also at introductions, where the wiring harness forming a wiring harness is inserted into a component. Even the widely used parallel connectors and end connectors are endangered by lack of longitudinal water tightness due to the ingress of moisture. As a result of insufficient longitudinal water tightness short circuits in the electrical system can occur, which can lead to serious malfunctions.

According to WO 96/16415, longitudinally watertight sections in predetermined areas of multi-core cable sets are produced in that the interspaces (gussets) present between the individual housings are filled in the sections to be sealed with a sealing compound which hardens after a heat and / or pressure treatment. In this known method, after completion of a wiring harness, for example, a commonly used in the automotive industry, the bündiförmige wiring set fanned so that the individual wires of the electrical system are first isolated and then fanned out parallel to each other, whereupon an adhesive tape with a sticky layer transverse to the longitudinal direction of fanned out Single cores is glued to the fanned lines. The material of the adhesive layer of the adhesive tape penetrates between the individual wires and forms after completion of the process a watertight block in the respective treated areas of the electrical system.

Instead of an adhesive tape with a preferably made of butyl rubber adhesive layer already plastic elements have been introduced into the sealed areas of an electrical system, which swell in heat treatment to an enlarged cross-sectional design or melt and foam during heat treatment, the closed spaces (gusset) are closed. Such measures are known from DE 36 31 769 A1.

More recently, it has been proposed to apply foam directly to the areas of on-board networks to be sealed off against longitudinal water, but only after completion of the on-board network station which still needs to be sealed.

All of these known measures for achieving longitudinally watertight sections in ladder sets have in common that they are tackled after completion of the vehicle electrical system to be sealed. Since modern on-board systems can well have more than 150 individual wires, and also on a single working day a barely manageable variety of different on-board networks for different needs to be made, these known methods to the requirement of manual pre- and rework, high effort in quality assurance and to high capital expenditure, which aggravates added that the work result very much depends on the human factor (worker dependency).

On-board electrical systems are used in vehicles to distribute electrical energy and electrical signals. These on-board electrical systems are predominantly made to customer specifications, which means that the respective on-board electrical systems are tailored to the wishes of the respective car buyer. The electrical system-forming is almost exclusively manual work, whereby for reasons of rationalization, high value is placed on the respective components of a vehicle electrical system before assembly to provide time and type exactly. These components are, for example, single cores, cables, connectors, housings and connectors. Forming of the vehicle electrical system is usually carried out on sloping mobile mounting boards of about 2 m in height and up to 12 m in length.

The example of the needs in the automotive industry makes it clear that the required wiring harnesses (wiring systems) depend on the scope and design of how much electrical wiring between the power source and consumers in each vehicle are required. Just imagine what consequences a moistened electrical system exerts on the transmission of electrical impulses (on-board computers). Depending on the customer's requirements, vehicles of the same type can require very different on-board electrical systems, depending on the special requests of the motor vehicle customer. On-board electrical systems are usually mounted on suitable mounting boards, the individual wires of a vehicle electrical system, which have been cut to the required lengths, are routed by hand according to a wiring diagram available for each vehicle electrical system.

Another disadvantage of the known method is that they provide for longitudinal water-tightness only at a finished vehicle electrical system. Assuming a multi-year life of a provided with such a harness vehicle, so there is a risk that after several years by mechanical effects, chemical agents or other effects, the initially achieved longitudinal water resistance is impaired or even destroyed. Occurs, for example, in the final phase of the useful life of such a vehicle on an event that requires a high longitudinal water-tightness, such a mechanically or chemically impaired sealing system can no longer fulfill its task.

From US-PS 5,298,284 it is known to use superabsorbent polymers (SAP) in the field of sealing technology to prevent the penetration of moisture and their propagation in the longitudinal direction in cable breaks, especially submarine cables. DE 198 59 728 A1 discloses a water-swellable hot-melt adhesive based on a tackifying resin, a water-dispersible EVA wax and an ethylene-acrylic acid ester copolymer, a water-soluble homopolymer or copolymer and a superabsorbent polymer powder.

The superabsorbent polymers referred to as SAP are based in many cases on weakly cross-linked polyacrylates, such as partially neutralized with sodium acrylic acid.

Liquid, solvent-free, cross-linking polyacrylates (SAP) are available for the production of swellable cable components. These allow swellable coatings of different support materials such as fabrics, films, fibers and game, wherein the liquid system forms a homogeneous, water-blocking layer that has good sealing properties in the swollen state.

The invention is therefore an object of the invention to provide a method for producing selbstabdichtender sections in multicore cable arrangements, in particular in on-board networks, which runs regardless of the care and / or the skill of a human worker quality assured and leads to line arrangements, especially on-board networks whose sealing points over long periods of time are safe. The invention is also directed to such a conduit arrangement.

This object is achieved by the features of claims 1 and 7.

Water-swelling polymers are the same and can be used all substances or processes that block by chemical and / or physical effects against water penetration.

Water-swelling polymers result in the same substances and / or processes that seal against water z. B. by

- surface tension

- Energy fields

- Molecular size differences or similar processes that occur or are present with or without the action of water. Preferred embodiments of the method according to the invention are specified in the subclaims.

In the manufacture of on-board networks is assumed that large quantities of pipeline material, which is provided in barrels, drums or rolls as so-called yard goods. On their way from the meter to the electrical system line sections are automatically cut to the desired lengths, stripped, welded, crimped, contacted, etc. The so prefabricated line types (individual wires) are formed by the staff on the assembly board to a vehicle electrical system.

The achievable with the present invention progress results from the fact that dimensionally fixed sealing points on previously precisely defined sections of individual wires with the help of a water-swelling material are brought about by automated means, in such a way that after completion of an individual wiring harness (wiring harness, line arrangement) the treated Sections meet. If an attack of moisture occurs on a line set equipped in this way, the water-swellable materials enveloping each individual vein over a given section in their longitudinal dimension absorb the attacking water with a strong increase in volume. The interaction of adjacent sealing points thus, so to speak, automatically forms a sealing block penetrating the entire bundle of cables (wiring harness), which effectively prevents the spreading of moisture (water).

In the context of the present invention, the aforementioned mode of operation makes it possible to characterize the longitudinally watertight sealing points as "self-sealing systems in cable bundles and components of land, air and water vehicles." Commercial SAP powders can have swelling volumes of more than 500 times their original volume to reach.

In the context of the invention, the water-swelling polymer can be used in a variety of forms, for example powdery, liquid, emulsified, as a gel or as a thermoplastic. The water-swelling polymer can be used without carrier material or with carrier material for Use come, are preferred as the carrier material tapes, yarns, fibers or nonwovens.

The invention will be described in more detail below with reference to exemplary embodiments with reference to the drawing. In this shows

1 shows a trained using the method according to the invention sealing in a bushing,

2 shows a sealing point produced by means of the invention in an introduction,

Fig. 3 is a formed by means of the invention sealing point in a parallel connector

4 shows a sealing point produced by means of the invention in an end connector,

5 an envelope of a water-swelling material on a single core (section),

6 shows schematically a water-swelling casing made of an adhesive tape on a single core of a cable set,

7 shows an undivided spout or sleeve with a water-swelling inner coating,

Fig. 8 is a split grommet whose Abdichtbereiche with a water-swelling

Polymer are provided,

9 shows a control box, which is provided with a water-swelling inner coating, and

10 shows a housing seal with an emergency seal in addition to a

Standard seal. For the application of the method according to the invention, a supply of individual wires of different length and different design (conductivity, load capacity) is provided in a known manner, for example, on so-called racks, of which the individual wires taken by hand for each on-board network individually predetermined shape scheme by hand and for forming a individual electrical system can be used. For the manufacture of a vehicle electrical system, goods sold by the meter are taken from the ring or barrel or a drum and cut to the required dimensions for the individual cores. Before the individual wires made of the sold by the meter are combined into a vehicle electrical system, it is ensured that these individual wires are assembled on at least one end, ie stripped or prepared with plugs or otherwise for further use. On their processing path from the unmanufactured meter goods to the trunk group of a vehicle electrical system, each individual core is automatically coated in at least one predetermined longitudinal section of the single wire and in a predetermined defined length with a water-swelling polymer, preferably a so-called. Superabsorbent polymer (SAP). The automatic coating of the individual cores takes place at predetermined spatial positions which correspond to the sections provided for the longitudinal water seals. The location of these automatically applied polymer coatings is chosen so that in the finished electrical system coated with the water-swelling polymer portions are adjacent to each other. Consequently, in the finished vehicle electrical system, the coated sections of all the individual wires are arranged in correspondence with one another in the same local position (position), namely the sealing point of the vehicle electrical system to be produced.

The compliance with the predetermined spatial positions (positions) and predetermined dimensions of the coatings can be achieved technically in various ways. As an example, a drip or spray device is called, which is arranged according to the predetermined location of the applied coating, and acted upon the individual cores successively in a common location with a defined amount of the water-swelling polymer. By suitable choice, for example the outlet opening of said dripping device, the longitudinal dimension of the polymer application can be determined on the surface of the individual cores. In the above examples, an SAP liquid or SAP emulsion is applied and finally dried. Alternatively, the water-swelling polymer (SAP) can be used in conjunction with a carrier material, such as fabrics, films, fibers, tiles or yarns. For example, the water-swelling material arranged on a carrier tape can be applied by automatically wrapping each individual wire to the desired spatial position and in the desired longitudinal dimension. Suitable SAP-coated carrier tapes have an adhesive coating on one side and the SAP coating on the other side. With the adhesive coating, such a band adheres to the surface of the single core.

After completion of an on-board network this has in at least one section on a self-sealing in moisture access, water-blocking system, which is composed of the applied in matching spatial position in the longitudinal dimension of each individual conductor water-swelling polymer coatings. If moisture (water) reaches such a sealing point, this water is immediately absorbed and firmly bound with considerable increase in volume of the swellable material. Existing damaged areas or existing cavities, especially in the interstices between adjacent individual cores, are sealed immediately and further penetration of the water is effectively prevented.

If a further penetration of moisture on the outer surface of a line set produced according to the invention is also to be prevented, then a sleeve or grommet can be applied to the outer circumference of the sealing point constructed from the multiplicity of sheaths. If moisture enters the area between the inner surface of the spout / sleeve and the outer surface of the vehicle electrical system, as discussed above, this moisture is absorbed by swelling of the water-swelling material present on the outer surface of the sealing point and a water-blocking seal is built up.

Fig. 1 shows schematically a sealing point 1 according to the invention formed in the passage opening of a partition wall between adjacent areas of a vehicle. The individual wires are designated by the reference numeral 2. Fig. 2 shows schematically a sealing point 1 produced by means of the invention in an introduction of individual wires 2 into a component. Fig. 3 shows schematically a formed by means of the invention sealing point 1 in a parallel connector for individual wires 2, wherein the parallel connector has a spout 4 and it contacted at the individual wires around Head acts. 4 shows schematically a sealing point 1 produced by means of the invention in an end connector with an outer cap 6. FIG. 5 shows schematically as a section a single core 2 with an envelope 8 made of a water-swelling polymer-coated adhesive tape. FIG. 6 shows schematically a water-swelling enclosure arranged on a single core 2, which consists of an adhesive tape with water-swelling polymer adhering thereto. In Figs. 5 and 6, the water-swelling polymer is applied to a surface of an adhesive tape whose other surface has an adhesive layer adhered to the surface of the single-wire 2.

Another protection of electrical systems against the ingress of moisture (water) is to seal the respective spatial connection of the sealing points 1 in the electrical system to the environment, such as a land, sea or aircraft, alike with the aid of a water-swelling polymer.

Preferred embodiments are described in FIGS. 7 to 10. FIG. 7 shows an undivided spout or sleeve 10 which has a water-swelling polymer coating hatched on at least part of its inner surface. FIG. 8 schematically shows a split spout, that is to say a spout 12, which normally comprises two parts of upper and lower shell, whose sealing regions are provided with a water-swelling polymer shown by hatching. When moisture enters the polymers instantaneously form a permanent water blockage, which protects the running in the spouts or sockets Bordnetzabschnitte moisture ingress.

Also switch boxes (e-boxes) and other housings (Fig. 9) can be sealed by means of inner coatings of a water-swelling polymer against condensation. For all seals in component systems shown in FIGS. 7 to 10, the respective sealing regions are premounted with fixed, preformed (eg stamped) or freely formed seals, which consist for example of strings or tapes. Furthermore, these seals can be made of plastic material, of pasty material or of liquid material. 10 shows an emergency seal 14 on a housing, this emergency seal being activated from a water-swelling polymer when a standard seal 16 should fail, for example due to porosity, an NBR / EPDM seal.

Claims

claims

1. A method for producing selbstabdichtender sections in multicore cable arrangements, in particular in on-board networks, in which a plurality of individual wires are formed into multicore cable arrangements, in particular electrical systems, and formed in predetermined portions of the line assemblies longitudinal water seals, wherein the individual wires before their merger to the multilayer wiring arrangement , in particular on-board networks, are automatically coated in at least one predetermined length in the longitudinal direction of the individual wire and in a predetermined defined amount with a water-swelling polymer, preferably a so-called superabsorbent polymer (SAP), and the positions of the coated portions of the individual wires are chosen so that the assembly of the individual cores, which are arranged adjacent to each other with the water-swelling polymer coated portions.

2. The method according to claim 1, characterized in that the water-swelling polymer is applied as a liquid or as an emulsion or as a powder automatically on the intended as sealing points sections of the individual wires.

3. The method according to claim 1, characterized in that the water-swelling polymer is applied automatically together with a band-shaped or filament-shaped carrier material to the intended as sealing points sections of the individual wires.

4. The method according to any one of claims 1 to 3, characterized in that a sleeve or grommet is applied to the outer circumference of the assembled electrical system in the region of the sealing point.

5. The method according to at least one of the preceding claims 1 to 4, characterized in that the individual cores are used as ready made by the meter with predetermined, preferably different cable dimensions and predetermined structure.

6. The method according to any one of the preceding claims 1 to 5, characterized in that the line arrangement, in particular electrical systems, are formed according to a predetermined shape scheme is provided in predetermined sections with one or more longitudinal water seals.

7. Multicore cable arrangement, in particular wiring harness or electrical system of a watercraft and / or land and / or aircraft, characterized by adjacent sections of individual wires of the line arrangement coated with a water-source polymer, preferably SAP (superabsorbent polymer) for longitudinal sealing of the individual wires against each other.

8. Use of swellable polymers for sealing sealing areas as moisture protection for sleeves or grommets (10) of electrical cables of all kinds.

9. Use of water-swelling polymers for sealing the parting surfaces of split spouts (12).

10. Use of water-swelling polymers as internal coating of electrical control boxes to protect against condensation.

11. Use of water-swelling polymers as an emergency seal for electrical housings.