Cable Sealing Device Junction Box Bulkhead Fitting
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Solution Overview
Problem
In motor coaches and similar vehicles, there is a need for a sealed fitting to prevent dust and water from entering the electrical junction box through which electrical cables pass, as existing solutions fail to provide a reliable water-tight and dust-tight seal.
Innovation Solution
A bulkhead fitting with a centering frame, clamping plates, and a sealing membrane that aligns cable passage holes on both sides, using a press-fit mechanism with a fastening post and nut to ensure a water-tight and dust-tight seal, and includes cable support cradles to guide and secure cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a bulkhead fitting is used to allow cable passage through the junction box wall, then cable connectivity is enabled, but dust and water can enter the junction box
Solution Approach 1:
A flexible sealing membrane with integrated grommets is used to seal around cables while allowing them to pass through. The membrane can deform to accommodate cable movement while maintaining the seal, preventing dust and water ingress while enabling cable connectivity.
Solution Approach 2:
Grommets serve as intermediary elements between the rigid bulkhead fitting and the flexible cables. These grommets provide a compliant interface that seals around the cables, allowing cable passage while blocking the path of dust and water.
2Object-affected harmful factors
If a sealed fitting is implemented to prevent dust and water ingress, then protection is improved, but cable alignment and passage precision are compromised
Solution Approach 1:
The sealing membrane's physical properties (flexibility, thickness) are optimized to balance sealing effectiveness with cable passage capability. The membrane can deform to accommodate cable variations while maintaining the seal, resolving the conflict between protection and alignment precision.
Solution Approach 2:
The sealing system transitions from a rigid fixed-geometry seal to a dynamic flexible membrane that can adapt its shape. This allows the seal to accommodate cable movement and alignment variations while maintaining dust and water protection.
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 solution effectively prevents dust and water ingress into the junction box, meeting IP65 standards for dust and water protection, ensuring reliable operation and reducing contamination.
Implementation Method 1
the post and nut applying clamping force between the first clamping plate and second clamping plate
Implementation Method 2
the sealing membrane is pressed between the first clamping plate and the flange to provide a water-tight and dust-tight seal
Implementation Method 3
The perforation in the sealing membrane is preferably configured for a press fit with a cable for that cable passage to provide a water-tight and dust-tight seal
Data Source
AI summary
A cable sealing device for an electrical junction box includes a centering frame mountable at a hole in a wall of the junction box, a first clamping plate having a plurality of cable passage holes, the first clamping plate being disposed on a first side of the centering frame within the first seat, a second clamping plate having an equal plurality of cable passage holes, the second clamping plate being disposed on a second side of the centering frame opposite the first side wherein the cable passage holes of the first clamping plate are aligned with the cable passage holes of the second clamping plate to define a plurality of cable passages and, a sealing membrane disposed between the first clamping plate and the flange of the centering frame, wherein portions of the sealing membrane are exposed at the plurality of cable passages and wherein at least one exposed membrane portion has a perforation to accept a cable.