Cable Entry Seal With Bellows for Non-Circular Conductors
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Solution Overview
Problem
Conventional systems fail to provide effective sealing protection for electrical enclosures against dust and water intrusion at entry points for conductors with non-circular cross-sectional profiles, particularly rectangular profiles, and are compromised by conductor bends that break seals.
Innovation Solution
A flexible sheath system with an anchor structure and fasteners is used to secure conductors of varying cross-sections, featuring a tapering structure and bellows section to accommodate different angles and sizes, combined with a sealing material to form a robust seal against dust and water entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sealing systems are used for electrical enclosures, then installation is simple, but sealing effectiveness against dust and water is compromised, particularly for non-circular conductors
Solution Approach 1:
The patent employs a flexible bellows section made of elastomeric material that can deform and conform to different conductor shapes and angles. This flexible membrane structure allows the seal to adapt to rectangular, circular, or irregular conductor profiles while maintaining sealing effectiveness against dust and water ingress.
Solution Approach 2:
The sealing system utilizes the elastic properties of the bellows section, which can change its geometric parameters (expansion, contraction, bending) in response to different conductor insertions. The material's viscoelastic characteristics allow it to deform during installation and then maintain a sealed state, adapting to various conductor orientations and profiles.
2Strength
If rigid sealing structures are used, then structural strength is improved, but adaptability to different conductor angles and sizes is reduced
Solution Approach 1:
The bellows section is constructed from elastomeric material that provides both flexibility and structural integrity. The corrugated design of the bellows allows it to bend and flex while maintaining its sealing capability, enabling accommodation of various conductor angles without compromising seal robustness.
Solution Approach 2:
The sealing system combines the elastomeric bellows section with a rigid anchor structure that includes a flange and mounting features. This composite construction allows the flexible portion to adapt to different conductor configurations while the rigid anchor provides strong attachment to the electrical enclosure, ensuring overall structural strength.
3Manufacturing precision
If a fixed-size sealing opening is used, then manufacturing precision is improved, but adaptability to varying conductor cross-sectional areas is lost
Solution Approach 1:
The bellows section's flexible nature allows it to deform and conform to conductors of varying cross-sectional areas. While the opening maintains consistent manufacturing dimensions, the elastomeric material can stretch, compress, and reshape itself to seal around different conductor sizes, from small gauge wires to large bus bars.
Solution Approach 2:
The sealing system transitions from a static rigid opening to a dynamic flexible structure. The bellows section can dynamically adjust its shape and size during conductor insertion and operation, allowing the same opening to accommodate various conductor dimensions while maintaining sealing effectiveness.
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 system effectively seals against dust and water ingress, maintaining electrical component performance by accommodating various conductor profiles and orientations, meeting IP55 and IP66 standards.
Implementation Method 1
applying a flexible sealing material around an interface between the conductor and the sheath at the receiving end to seal the interface
Implementation Method 2
material of the sheath is compressed between the anchor ring and the wall to form a seal between the sheath and the wall
Data Source
AI summary
Connectors and methods for providing a seal between a conductor and a wall of an electrical enclosure that includes an opening to receive the conductor therethrough and a method for providing. A connector can include a sheath configured to surround the conductor along a length of the conductor and an anchor structure internal to the sheath. The anchor structure can include fastener openings arranged to receive a plurality of fasteners that extend through the wall and through material of the sheath, to couple the sheath to the electrical enclosure with the material of the sheath between the anchor structure and the wall of the electrical enclosure to provide a seal.