Impervious cable connected electrical component assembly

Abstract

An impervious cable connected electrical component assembly is provided wh includes an electrical component which has a conductive wire extending therefrom. An impervious container is provided which has an open top and a closed bottom. The electrical component is located within the container with its conductive wire extending out of and beyond the container's top. A cable is provided which has a conductive wire within an impervious sheath. A lengthwise portion of this wire is exposed. The conductive wire extending from the top of the container and the exposed conductive wire portion of the cable are electrically joined at a junction outside the container. An impervious sleeve is bonded to the cable sheath so as to hermetically seal the wire junction along the cable. The open top of the container and the sleeve are bonded to hermetically seal the electrical component. With this arrangement the assembly can be easily constructed with minimal effect on the electrical component and, after construction, the assembly can be used with maximum protection of the electrical component.

What is claimed is: 
     
       1. A method of constructing an impervious assembly wherein the assembly includes an electrical cable and an electrical component, each having at least one conductive wire within a sheath comprising the steps of: exposing a conductive wire portion of said electrical cable and said electrical component conductive wire;   providing a thermoplastic container which has a top and a bottom;   placing the electrical component within the container with the exposed conductive wire portion extending beyond the top of the container so as to be in proximity to the exposed conductive wire portion of the cable;   joining the exposed conductive wire portions of the electrical component and the cable to form an electrically conductive junction;   encasing the electrical wire junction and portions of the wire sheath extending from the junction in a thermoplastic sleeve so as to hermetically seal the wire junction; and   applying localized heat sufficient to bond the top of the container to the sleeve to hermetically seal the electrical component.   
     
     
       2. The method as claimed in claim 1 wherein: the material of the cable sheath, the sleeve and the container comprise "Surlyn".   
     
     
       3. The method as claimed in claim 2 wherein: the container comprises a pocket; and   the step of bonding the top of the container to the sleeve comprises bonding the top of the pocket to the sleeve.   
     
     
       4. The method of claim 1 wherein the step of applying localized heat comprises the step of ultrasonic welding the container to the sleeve. 
     
     
       5. The method of claim 1 wherein the step of applying localized heat comprises the step of vibration welding the container to the sleeve. 
     
     
       6. The method of claim 1 wherein the step of encasing the electric wire junction and portions of the wire sheath extending from the junction in a thermoplastic sleeve comprises the step of injection molding the sleeve. 
     
     
       7. The method of claim 1 further comprising the step of placing a material in the container to protect the electrical component. 
     
     
       8. The method of claim 7 wherein said material comprises polyurethane. 
     
     
       9. The method of claim 7 wherein said material comprises potting compound. 
     
     
       10. The method of claim 7 wherein said material comprises epoxy.