Cable Overmolding Seal Structure for Clean High-Pressure Injection
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Solution Overview
Problem
Existing methods for producing cables with functional elements like plug connectors and cable outlets result in mechanically weak and environmentally unsealed connections due to high pressure requirements, and are inefficient and costly due to manual processing.
Innovation Solution
A method where a line is pressed against a seal surface by the molding compound within a molding tool, using a conical seal element integrated into the sheath to create a secure, environmentally sealed connection, allowing for automated production and improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high pressures are applied in the injection molding process to create an environmentally sealed connection, then the sealing quality is improved, but the line may escape from the mold or create unclean transitions
Solution Approach 1:
A seal element is introduced as an intermediary component between the line and the mold cavity. This seal element absorbs the high pressure forces, preventing material escape while maintaining clean transitions. The seal element acts as a mediator that enables high-pressure sealing without directly transmitting the full force to the line-mold interface.
Solution Approach 2:
The sealing function is segmented from the main injection molding process by introducing a separate seal element. This segmentation allows the sealing function to be optimized independently, with the seal element specifically designed to handle high pressures while the main molding process maintains clean transitions.
2Stability of the object's composition
If the line is manually fixed in the injection mold to ensure secure positioning, then the connection stability is improved, but the process complexity and production time increase
Solution Approach 1:
The line itself provides the positioning function through its own geometry and the seal element interaction, eliminating the need for external fixing mechanisms. The line is inserted into the cavity and positioned by the seal element engagement, allowing automatic positioning without manual intervention or complex fixing devices.
Solution Approach 2:
The fixing function is extracted from the injection mold structure and transferred to the seal element and line combination. This removes the need for separate fixing elements and simplifies the mold design, enabling automated line insertion and positioning.
3Reliability
If the line is severely squeezed to ensure a secure seal, then the sealing quality is improved, but mechanical weak points are created in the cable
Solution Approach 1:
The seal element serves as a mediator that distributes sealing forces uniformly across the line surface. Instead of concentrating squeezing forces at specific points, the seal element creates a distributed pressure profile that achieves effective sealing while minimizing localized stress concentrations that would create weak points.
Solution Approach 2:
The pressure distribution parameter is changed from concentrated high pressure to distributed moderate pressure through the seal element. This parameter change maintains the integrated seal quality while reducing peak stresses that would compromise cable mechanical strength in the transition region.
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
This method enables the production of cables with robust, environmentally sealed connections and reduces production costs by allowing for automated processing and improved mechanical stability.
Implementation Method 1
a molding compound being injected into the cavity of the molding tool in a pressurized manner
Implementation Method 2
the line is pressed against a seal surface of the cavity by the pressure of the molding compound
Implementation Method 3
the line closes the cavity at the seal surface
Data Source
AI summary
The invention relates to a method for producing a cable, comprising both a molding tool with a cavity and with at least one first opening, and a line, said line consisting of at least one wire and a sheath surrounding the at least one wire. According to the invention, the line is inserted into the cavity and is guided out of the cavity via at least the first opening. A molding compound is injected into the cavity of the molding tool in a pressurized manner, wherein the line is pressed onto a seal surface of the cavity by means of the pressure of the molding compound, and the line closes the cavity at the seal surface.