Cable Sealing Assembly Using Heat-Shrink Tube and Gap Filler
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Solution Overview
Problem
Existing electrical devices face issues with poor adhesion of overmolding materials, leading to ambient medium creeping, damage to cable insulation and wires, and increased brittleness due to thermoset material creeping into gaps between cable wire and insulation, which compromises the tightness and durability of the electrical connection.
Innovation Solution
A heat-shrink tube filled with a sealing material is applied around the cable insulation and cable wire, shrunk to force the material into gaps, preventing thermoset overmolding material from entering these spaces and ensuring a durable, flexible seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermoset overmolding material is used for sealing, then sealing coverage is improved, but adhesion to cable insulation deteriorates
Solution Approach 1:
A heat-shrink tube is introduced as an intermediary component between the cable insulation and the thermoset overmolding material. The tube provides a bonding layer that improves adhesion while maintaining sealing coverage, preventing the thermoset material from directly contacting the cable insulation.
Solution Approach 2:
The solution uses a composite structure combining the heat-shrink tube material with the thermoset overmolding material. This composite approach leverages the advantages of both materials: the tube provides good adhesion to cable insulation while the thermoset material provides comprehensive sealing.
2Reliability
If thermoset overmolding material is applied, then sealing is improved, but cable insulation and wires are damaged
Solution Approach 1:
The heat-shrink tube is installed beforehand to create a protective cushioning layer between the cable insulation and the rigid thermoset overmolding material. This cushioning prevents direct contact and potential damage during the overmolding process and subsequent wear.
Solution Approach 2:
The heat-shrink tube acts as a flexible protective shell that conforms to the cable insulation surface. This flexible barrier protects the cable insulation from damage while allowing the rigid thermoset material to be applied for sealing purposes.
3Reliability
If thermoset overmolding material is used, then sealing is achieved, but brittleness increases
Solution Approach 1:
The solution applies different material properties to different locations: the heat-shrink tube provides flexibility where needed (at the cable insulation interface), while the thermoset overmolding material provides sealing where required. This local differentiation of material properties prevents overall brittleness while maintaining sealing effectiveness.
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 enhances the sealing properties of electrical devices, maintaining cable insulation elasticity and preventing damage, while ensuring a long-lasting, tight electrical connection.
Implementation Method 1
applying heat to the heat-shrink tube such that the heat-shrink tube at least partially shrinks
Data Source
AI summary
Various embodiments of the teachings herein include an electrical device comprising: a cable wire; a cable insulation arranged around the cable wire such that a section of the cable wire at least partially longitudinally protrudes out of the cable insulation; a heat-shrink tube at least partially arranged around the cable insulation and at least partially around the section of the cable wire; and a sealing material at least partially inside the cable insulation thereby sealing any gaps between the cable wire and the cable insulation.