Foamable Cross-Linked Connector Sealing Material for Gap Filling
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Solution Overview
Problem
Conventional sealing methods for electrical connectors, such as sealing rings, glue fillings, and insert injection moldings, struggle to meet the increasingly stringent sealing requirements of complex connector structures, and the glue filling process is complex and inconvenient.
Innovation Solution
A foamable cross-linkable thermoplastic material composed of a matrix polymer, cross-linking agent, and foaming agent, which can be preformed into shapes like sealing rings or tubes, and undergoes foaming and cross-linking at high temperatures to fill gaps and enhance bonding, using a weight ratio of 1-5:100 for both agents to the matrix polymer, and a foaming temperature above the matrix's melting point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sealing rings or insert injection molding are used, then sealing structure is simple, but sealing performance is insufficient for complex connector structures
Solution Approach 1:
The patent uses a composite sealing material comprising a thermoplastic elastomer matrix and a crosslinking agent. The thermoplastic elastomer provides flexibility and sealing capability, while the crosslinking agent forms a three-dimensional network structure upon heating to enhance mechanical strength and sealing performance. This composite approach allows the sealing structure to maintain simplicity while achieving superior sealing performance for complex connector structures.
Solution Approach 2:
The patent utilizes temperature-dependent parameter changes to achieve sealing. The sealing member is heated to a temperature above the melting point of the thermoplastic elastomer, causing it to soften and flow into the sealing space. Upon cooling, the material solidifies and forms a secure seal. This parameter change (temperature) allows the simple sealing structure to adapt to complex connector geometries and achieve high sealing performance.
2Reliability
If glue filling is used to seal connectors, then sealing performance can be improved, but the manufacturing process becomes complex and inconvenient
Solution Approach 1:
The patent extracts the sealing function from a separate complex manufacturing process (glue filling) and integrates it into the connector housing itself. The sealing member is incorporated as an integral part of the housing structure, eliminating the need for separate glue filling operations. This integration maintains high sealing performance while significantly simplifying the manufacturing process.
Solution Approach 2:
The sealing member is designed to perform the sealing function autonomously through its own material properties and structural design. When heated, the thermoplastic elastomer softens and automatically flows into the sealing space, forming a seal without requiring external adhesive materials or complex filling processes. This self-service mechanism simplifies manufacturing while maintaining effective sealing.
3Strength
If cross-linking agent and foaming agent are added to matrix polymer, then bonding strength and sealing performance are enhanced, but material composition becomes more complex
Solution Approach 1:
The patent merges multiple functions into a single integrated sealing member. The thermoplastic elastomer matrix provides baseline sealing and bonding capabilities, the crosslinking agent enhances bonding strength through three-dimensional network formation, and the foaming agent creates a foam structure that improves adhesion to mating surfaces. These components are combined in a single material system rather than applying separate treatments, simplifying the overall material composition while achieving enhanced performance.
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 material provides improved sealing and bonding performance with a simpler manufacturing process, filling gaps and enhancing adhesion between terminals and housings through foaming and cross-linking, suitable for high-temperature injection molding of engineering plastics.
Implementation Method 1
a foaming agent... A cross-linking foaming temperature of the thermoplastic material is equal to or higher than the melting point of the matrix polymer
Implementation Method 2
a cross-linking agent... A weight ratio of the cross-linking agent to the matrix polymer is 1-5:100
Data Source
AI summary
A foamable cross-linkable thermoplastic material comprises a matrix polymer of any one or a mixture of two or more of polyethylene (PE), ethylene vinyl acetate copolymer (EVA) and polypropylene (PP), a cross-linking agent, and a foaming agent. A weight ratio of the cross-linking agent to the matrix polymer is 1-5:100. A weight ratio of the foaming agent to the matrix polymer is 1-5:100. A cross-linking foaming temperature of the thermoplastic material is equal to or higher than the melting point of the matrix polymer.