Multi-Core Cable Plug Sealing With One-Piece TPU Insert
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for assembling electrical plugs with sheathed cables face challenges in achieving a simple and reliable moisture seal, particularly due to complex sealing element designs and assembly processes.
Innovation Solution
A one-piece, monolithic sealing element made of softer thermoplastic polyurethane material is applied to the wires and inserted into a plug housing, with a cone shape and controlled injection pressure ensuring a strong seal, simplifying the assembly process and enhancing sealing efficacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-part sealing element (two half-shells) is used, then the sealing effect can be achieved, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The patent combines two separate half-shell sealing elements into a single one-piece sealing element made of thermoplastic polyurethane material. This monolithic design eliminates the need to assemble multiple parts, simplifying the assembly process while maintaining the sealing function. The single-piece construction is pushed onto the cores as one unit and then into the receptacle, reducing assembly steps and time.
Solution Approach 2:
The sealing element is designed with individual feedthroughs for each wire/core, creating segmented pathways within the monolithic structure. This allows each core to be sealed independently while maintaining the integrity of the overall sealing element, combining the benefits of both segmentation and unity.
2Device complexity
If a one-piece sealing element is used, then the assembly process is simplified, but ensuring reliable sealing against moisture ingress becomes more challenging
Solution Approach 1:
The patent specifies using thermoplastic polyurethane material with particular properties (softness, elasticity) that enable the one-piece sealing element to deform and conform to the receptacle geometry. The material parameters are selected to ensure reliable sealing while maintaining ease of assembly. The press-in force during assembly further modifies the material parameters temporarily to achieve the seal.
Solution Approach 2:
The sealing element features a conical shape with a tapered geometry that facilitates insertion into the receptacle and ensures uniform contact pressure distribution. The curved/conical surface allows the sealing element to be pressed in smoothly while maintaining consistent sealing contact, combining simplicity with reliability.
3Productivity
If automated assembly methods are used, then productivity increases, but the requirement for precise sealing element design increases
Solution Approach 1:
The sealing element is designed to be self-positioning and self-sealing during automated assembly. The conical shape and material properties enable the component to automatically orient itself and create the seal under press-in force without requiring complex positioning mechanisms or high-precision alignment systems in the automated assembly equipment.
Solution Approach 2:
The use of thermoplastic polyurethane material with specific viscoelastic properties allows the sealing element to deform during automated insertion and then maintain the seal. The material parameters are chosen to accommodate variations in assembly speed and force while ensuring consistent sealing quality, enabling automated high-speed assembly.
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 approach enables efficient, automated assembly with improved sealing performance, reducing complexity and costs while ensuring effective moisture resistance.
Implementation Method 1
when spraying or pouring on the casing, a longitudinally directed press-in force is exerted, so that the sealing element is pressed into the receptacle by the press-in force
Implementation Method 2
The sealing element is expediently designed in the manner of a cone element, i.e. it tapers in the longitudinal direction. As a result, the injection process and the associated press-in force improve the sealing effect
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a method for assembling a plug (2) on a multi-core sheathed cable (4), which extends in a longitudinal direction (20) and has multiple wires (10) surrounded by a cable sheath (12), wherein a sealing element (16) made of a sealing material is applied to the multiple wires (10), wherein the sealing element (16) has an individual passage (17) through the sealing material for each of the wires (10). Subsequently, the wires (10) are assembled in a plug housing (6), wherein the plug housing (6) has an opening (22) at the rear end thereof, and the sealing element (16) is inserted into the opening (22) and shifted preferably along the wires (10) such that the sealing element (16) sits in the opening (22) in a sealing manner. A sealing coating (8) is then applied, which extends from the rear end of the plug housing (6) to the cable sheath (12). The invention also relates to a plug (2).