Cable Resin Mold Inflow Passage Design for Waterproofing
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Solution Overview
Problem
Conventional rotation sensors face moisture ingress issues due to gaps between the cable sheath and the molded resin, which can compromise detection accuracy.
Innovation Solution
A method for producing a cable with a resin mold involves injecting molten resin into a die with a specific inflow passage design that ensures the sheath is securely molded, eliminating gaps and enhancing waterproofing by solidifying the resin around the cable and sensor, thereby preventing moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional molding is used with dies having grooves smaller than cable outer diameter, then the cable is held securely during molding, but gaps still form between the sheath and molded resin allowing moisture ingress
Solution Approach 1:
The patent changes the physical state parameter of the resin from solid to molten state during molding. By injecting molten resin that flows through the inflow passage and heats the sheath, the resin adapts to fill all gaps and conform precisely to the sheath surface, eliminating voids and ensuring complete waterproofing without requiring pre-formed grooves
Solution Approach 2:
The inflow passage acts as an intermediary channel that guides the molten resin to flow directly over the sheath surface before entering the reservoir. This intermediary path ensures the sheath is thoroughly heated and coated with resin, creating a seamless bond that prevents moisture ingress while maintaining structural integrity
2Ease of manufacture
If the sheath and molded resin are not in close contact around the entire circumference, then molding may be easier, but detection accuracy of the sensor element is compromised due to moisture reaching the sensor
Solution Approach 1:
By changing the resin to a molten state during injection, the material becomes highly fluid and adaptable, automatically conforming to the sheath's entire circumference including any irregularities. This ensures complete contact and sealing around the sensor area, protecting detection accuracy while simplifying the molding process
Solution Approach 2:
The molten resin is injected to flow through the inflow passage and coat the sheath surface before final solidification occurs. This preliminary heating and coating action ensures the resin adheres completely to the sheath in all areas, creating a protective seal that prevents moisture from reaching the sensor element
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 significantly enhances waterproofing, ensuring the integrity of the sensor's detection accuracy by sealing the interface between the cable sheath and the resin mold, preventing moisture from reaching the sensor element.
Implementation Method 1
a portion of the sheath being molten by heat of the molten resin
Data Source
AI summary
A method for producing a cable with a resin mold including a cable section comprising an electric wire and a sheath comprising a synthetic resin covering the electric wire, and a resin mold section into which a portion of the sheath is molded by a resin is provided. A portion of the cable section is received in a receiving space in a die formed with a molten resin inlet, an inflow passage, and a resin reservoir therein. A molten resin is injected from the inlet into the receiving space. A portion of the injected molten resin flows through the inflow passage and is retained in the resin reservoir. The portion of the sheath is molten by heat of the molten resin. The molten resin is solidified to thereby form a molded resin product. Its unnecessary portion solidified in the resin reservoir is removed from the molded resin product.