Cable Sealing Resin Bonding via Welded Intermediary Member
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Solution Overview
Problem
Existing methods for sealing electronic apparatuses with resin to maintain environmental resistance are costly and may not adequately secure the connection between cables and the sealing resin, especially in harsh environments with temperature changes and exposure to oils.
Innovation Solution
A manufacturing method involving a bonding intermediating member with a cylindrical base and extension, welded to the cable sheath, and a sealing resin that fills the internal space defined by the case and clamp, allowing for reduced manufacturing costs and improved material selection for enhanced environmental resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a ring cord or two-color molding member is formed through insert molding to cover the cable end, then the bonding force between the cable and sealing resin part is improved, but manufacturing costs increase due to the need for specialized molds and modified molding conditions
Solution Approach 1:
The patent introduces a bonding intermediating member as a mediator between the cable and sealing resin part. This member has a first portion that bonds to the cable and a second portion that bonds to the sealing resin part, enabling strong bonding without requiring complex insert molding processes. The intermediating member simplifies manufacturing while maintaining or improving bonding strength.
2Reliability
If materials with excellent oil resistance are used for the ring cord or two-color molding member, then environmental resistance is improved, but the materials are not suitable for insert molding
Solution Approach 1:
The bonding intermediating member is divided into multiple portions with different functions: a first portion for bonding to the cable and a second portion for bonding to the sealing resin part. This segmentation allows each portion to be made from materials optimized for its specific function, including oil-resistant materials that would not be suitable for insert molding, while using conventional molding for other portions.
3Ease of operation
If the cable is merely held by an elastically deformable clamp, then the cable installation is simplified, but the bonding force is insufficient and separation may occur in connection sections
Solution Approach 1:
The bonding intermediating member serves as a mediator between the clamp and the cable, providing the necessary bonding strength that the clamp alone cannot achieve. The intermediating member's first portion bonds to the cable while the clamp holds the assembly, maintaining installation simplicity while ensuring sufficient bonding force to prevent separation.
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 secures a strong bonding force between the cable and the sealing resin, reducing the risk of separation and enhancing environmental resistance in harsh conditions while simplifying manufacturing and expanding material options.
Implementation Method 1
a bonding intermediating member that is made of a resin and joined to the cable... fixing the bonding intermediating member to the cable by welding the base onto the sheath
Data Source
AI summary
To provide an electronic apparatus which enables manufacturing costs to be reduced and a range of selection of materials for resin components to be widened. An electronic apparatus (1A) includes a case (10), a cable (30) drawn out from the case (10), a bonding intermediating member (40) that is made of a resin and joined to the cable (30), a cylindrical clamp (50) holding the cable (30), and a sealing resin part (60) filling an internal space defined by the case (10) and the clamp (50). The cable (30) has a core wire (31) and a sheath (33) that is made of a resin covering the core wire (31) and the core wire (31) is exposed not to be covered by the sheath (33) at an end of the cable (30). The bonding intermediating member (40) has a cylindrical base (41) covering an outer circumferential face of the sheath (33) and an extension part (42) extending from the base (41) and bonding to the sealing resin part (60). The bonding intermediating part (40) is fixed to the cable (30) by welding the base (41) onto the sheath (33).