Electric Wire Connector Sealing Layer Adhesion
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Solution Overview
Problem
Conventional electric wires with connectors using silicone insulators face challenges in achieving sufficient adhesiveness between the insulator and the connector housing, leading to poor water-blocking abilities due to the low adhesiveness of silicone materials.
Innovation Solution
The use of a sticky adhesive as a sealing layer between the insulator and the connector housing, specifically employing silicone-based or synthetic rubber-based sticky adhesives that are compatible with the insulator and resin materials, ensuring high adhesiveness and improved water-blocking capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a common adhesive is used to seal between the silicone insulator and connector housing, then the adhesive strength is insufficient at the interfaces, but using a sticky adhesive ensures high adhesiveness at both interfaces
Solution Approach 1:
The patent changes the key parameter of adhesive properties by selecting a sticky adhesive with specific characteristics (silicone-based or synthetic rubber-based) that can form strong bonds with both silicone insulators and resin connector housings. This parameter change resolves the contradiction by providing sufficient adhesive strength while maintaining water-blocking reliability.
Solution Approach 2:
The patent employs a composite sealing layer formed by combining sticky adhesive with the insulator and connector housing materials. This composite approach creates a multi-material interface that leverages the adhesive's bonding capabilities to bridge the silicone-insulator and resin-housing interfaces, simultaneously achieving high adhesiveness and reliable water blocking.
2Temperature
If silicone insulator is used for high heat resistance, then adhesiveness is poor, but using sticky adhesive compensates for this deficiency
Solution Approach 1:
The sticky adhesive acts as an intermediary material between the silicone insulator and the resin connector housing. This mediator overcomes the poor adhesiveness of silicone by providing a bonding interface that adheres well to both materials, allowing the silicone insulator to maintain its heat resistance properties while achieving sufficient bonding strength through the adhesive layer.
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 implementation of sticky adhesives enhances the adhesiveness at both interfaces, preventing water infiltration and maintaining excellent water-blocking abilities in the wire harness.
Implementation Method 1
a sealing layer provided between a surface of the insulator and the connector housing covering an outer circumference of the surface of the insulator at the end of the insulated electric wire, wherein the sealing layer is constituted by a sticky adhesive
Data Source
AI summary
An electric wire with a connector in which high adhesiveness can be ensured at both the interface between an insulator and a sealing layer and the interface between a connector housing and the sealing layer, and a wire harness using this electric wire with a connector are provided. The electric wire with a connector includes an insulated electric wire including a conductor and an insulator containing silicone with which the outer circumference of the conductor is coated, a connector terminal connected to a portion of the conductor exposed by stripping a portion of the insulator, a connector housing made of a resin in which an end of the insulated electric wire and a portion of the connector terminal are embedded, and a sealing layer provided between the surface of the insulator and the connector housing covering the outer circumference of the surface of the insulator at the end of the insulated electric wire. The sealing layer is constituted by a sticky adhesive.