Thermoplastic Adhesive Waterproofing for Core Wire Bundles
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Solution Overview
Problem
Existing waterproofing methods for electric wires are limited by terminal shape, require complex viscosity management, and often result in unstable or incomplete sealing due to the use of low-viscosity materials, which restricts their application and effectiveness.
Innovation Solution
A waterproofing structure and method involving a covered electric wire with a core wire bundle expanded portion, where the insulating covering is removed to expose the core wires, and a thermoplastic adhesive is used to fill the gaps between the wires and coverings, forming a mold portion that prevents water ingress without being limited by terminal shape or requiring complex viscosity management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mold portion is used to waterproof the terminal crimp part, then waterproof performance is improved, but the terminal shape is limited by the metal mold and the mold portion increases in size
Solution Approach 1:
The invention changes the physical state of the adhesive from solid to liquid by heating, allowing it to flow and adapt to different terminal shapes. The adhesive is heated to a temperature where it becomes liquid, fills the terminal crimp part, and then solidifies upon cooling, providing waterproofing without being constrained by mold geometry.
Solution Approach 2:
The invention replaces the mechanical mold system with a thermal process. Instead of using a physical mold to shape and constrain the waterproofing material, the invention uses temperature control to change the adhesive's viscosity, allowing it to naturally conform to the terminal shape and provide sealing.
2Ease of manufacture
If a low-viscosity material is dripped onto the terminal crimp part, then the process is simple, but stable waterproof performance is not obtained due to drooping and lack of material
Solution Approach 1:
The invention controls the temperature parameter to change the adhesive's viscosity dynamically. During application, the adhesive is maintained at a temperature where it has optimal flow characteristics for complete filling without drooping. After filling, cooling solidifies the adhesive to provide stable waterproof performance.
Solution Approach 2:
The invention performs preliminary heating of the adhesive before application to ensure it has the correct fluidity for complete filling of the terminal crimp part. This preliminary preparation prevents both drooping and insufficient filling, achieving stable waterproof performance.
3Ease of operation
If a low-viscosity water sealing agent is used to fill the core wire exposed portion, then filling is easy, but complex viscosity management and attachment to other components are required
Solution Approach 1:
The invention replaces complex viscosity management systems with a simple thermal control system. By controlling temperature, the adhesive's viscosity is automatically adjusted to the appropriate level for filling, eliminating the need for separate viscosity measurement and management procedures.
Solution Approach 2:
The adhesive material serves its own viscosity control function through temperature changes. The material naturally transitions from a fluid state during application to a solid state after filling, providing self-regulating viscosity control without requiring external management systems.
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 approach provides a compact, high-performance waterproofing solution that is not influenced by terminal type, offers increased freedom in sealing position, and eliminates the need for low-viscosity materials and complex viscosity management, ensuring effective prevention of water entry into electric wires.
Implementation Method 1
a mold portion that is molded to surround the core wire bundle expanded portion by cooling and solidifying a thermoplastic adhesive filling between the core wires in the core wire bundle expanded portion by hot melting
Implementation Method 2
a mold portion that is molded to surround the core wire bundle expanded portion by cooling and solidifying a thermoplastic adhesive filling between the core wires
Data Source
AI summary
A waterproofing structure in a core wire includes a covered electric wire in which a plurality of core wires are covered with an insulating covering, a core wire bundle expanded portion in which the core wires of an intermediate core wire exposed portion are separated from each other and expanded in diameter by removing a part of the insulating covering, and a mold portion that is molded to surround the core wire bundle expanded portion by cooling and solidifying a thermoplastic adhesive filling between the core wires in the core wire bundle expanded portion by hot melting, together with the insulating coverings at both sides between which the intermediate core wire exposed portion is interposed.