Electric Cable Connecting Structure Waterproofing
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Solution Overview
Problem
Existing connecting structures for electric cables, particularly those involving heterogeneous metals like copper and aluminum, face issues with waterproofing, leading to contact corrosion due to capillary phenomena, especially when not adequately covered with insulators, resulting in increased time and cost for optimization and reliability verification.
Innovation Solution
A connecting structure and method utilizing a heat-shrink tube with hot-melt applied on the inner surface or circumference to seal gaps between cores and covers, ensuring a waterproof connection by solidifying the hot-melt within the tube, preventing moisture ingress and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a short copper electric cable is connected between the terminal and the aluminum electric cable to prevent contact corrosion, then contact corrosion is prevented, but water can enter through gaps between cores and covers causing insulation defects
Solution Approach 1:
The patent applies nesting by placing the heat-shrink tube inside the insulator cover, creating a nested structure where the tube is contained within the cover. This nested arrangement ensures that the waterproof seal is positioned within the protective insulation layer, preventing water from reaching the connection portion while maintaining structural integrity.
Solution Approach 2:
The heat-shrink tube acts as a flexible shell that conformally wraps around the connection portion. When heated, the tube shrinks to tightly seal gaps between cores and covers, creating a waterproof barrier. This flexible shell approach effectively prevents water ingress while adapting to the irregular geometry of the connection area.
2Device complexity
If the connection portion is not covered with insulator, then the structure is simpler, but contact corrosion occurs due to capillary phenomena
Solution Approach 1:
The patent applies preliminary action by pre-positioning the heat-shrink tube on the connection portion before final assembly. The tube is already in place to prevent water ingress through capillary phenomena, eliminating the need for additional corrosion protection measures and maintaining structural simplicity while ensuring reliability.
3Device complexity
If heterogeneous metals are directly connected, then the connection is simpler, but contact corrosion occurs
Solution Approach 1:
The patent introduces a copper cable as an intermediary element between the aluminum electric cable and the terminal. This mediator prevents direct contact between heterogeneous metals (aluminum and copper alloy), eliminating galvanic corrosion. The copper cable serves as a transition component that connects to both aluminum and copper alloy without causing corrosion.
4Reliability
If a waterproof structure is added to prevent water ingress, then corrosion is prevented, but the manufacturing process becomes more complex
Solution Approach 1:
The heat-shrink tube applies self-service by automatically shrinking to the correct size when exposed to heat, creating a tight seal without requiring additional fastening operations or complex assembly steps. The material's thermal response provides the sealing action itself, simplifying the manufacturing process while ensuring effective waterproofing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively prevents contact corrosion and insulation defects by creating a waterproof seal between the cores and covers, reducing the risk of moisture-induced issues and maintaining connection reliability with a simpler and cost-effective process.
Implementation Method 1
a tube which is shrunk in a state where the tube accommodates thereinside the portion of the first core and the portion of the second core which are connected to each other
Implementation Method 2
an inside of the tube except for the portion of the first core and the portion of the second core is filled with cured hot-melt
Data Source
AI summary
There is provided a connecting structure for electric cables. A first electric cable includes a first core and a first cover covering the first core. A portion of the first core is exposed from an end of the first cover. A second electric cable includes a second core made of a different metal from that of the first core and a second cover covering the second core. A portion of the second core is exposed from an end of the second cover. A tube is shrunk in a state where the tube accommodates thereinside the portion of the first core and the portion of the second core which are connected to each other. An inside of the tube except for the portion of the first core and the portion of the second core is filled with cured hot-melt.