Crimped Cable Wall Connector for Gasket-Free High-Temperature Sealing
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Solution Overview
Problem
Existing cable connectors require precise and expensive machining, and often rely on gaskets that can be compromised by high temperatures, leading to leakage or damage to the cable.
Innovation Solution
A method and connector design that uses a profiled sleeve seated in a wall opening, where axial deformation forms an outer ring, and radial crimping secures the cable within a through opening, eliminating the need for a gasket between the wall and connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gasket is used between the wall surface and connector to ensure sealing, then sealing performance is improved, but the connector becomes vulnerable to high temperatures causing leakage or cable damage
Solution Approach 1:
The invention removes the gasket component from the sealing system. Instead of using a separate gasket between the wall and connector, the connector body itself is designed with a deformation zone that creates a sealing mechanism through plastic deformation, eliminating the temperature-sensitive gasket material entirely.
Solution Approach 2:
The invention changes the sealing mechanism from relying on elastomeric material properties (gasket) to relying on plastic deformation of the metal connector body. The deformation zone undergoes permanent shape change under axial load to create the seal, which is insensitive to temperature variations.
2Strength
If a threaded cup is used to clamp the gasket, then the gasket is secured, but the gasket and cable experience displacement and rotation leading to damage or leakage
Solution Approach 1:
The invention removes the threaded cup component entirely. The clamping function is integrated directly into the connector body through the deformation zone, which is radially crimped to clamp the cable without requiring a separate threaded fastening mechanism that causes rotation and displacement.
Solution Approach 2:
The invention merges the clamping function with the connector body itself. The deformation zone serves both as the mounting interface for securing the connector to the wall and as the cable clamping mechanism, eliminating the need for separate threaded components.
3Reliability
If traditional multi-part connectors with threaded assembly are used, then sealing can be achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention merges multiple functions into a single integrated connector body: the mounting interface, the sealing mechanism, and the cable clamping function are all incorporated into one piece. This eliminates the need for separate gaskets, threaded cups, and assembly steps, simplifying both structure and manufacturing.
Solution Approach 2:
The connector body is pre-formed with a deformation zone during manufacturing. This preliminary preparation allows the connector to be simply pressed into the wall opening and then radially crimped, eliminating the need for threaded assembly operations during installation.
4Manufacturing precision
If precise machining is used to produce threaded connectors, then assembly accuracy is improved, but production cost increases
Solution Approach 1:
The connector body is pre-formed with the deformation zone geometry during manufacturing. This preliminary action eliminates the need for precise threading and machining operations, allowing the use of simpler, more cost-effective forming processes while maintaining functional accuracy.
Solution Approach 2:
The invention changes the manufacturing approach from precision machining of threaded features to plastic deformation forming. The deformation zone is created through forming processes that are less costly and less precision-intensive than traditional threading operations.
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 provides a simple, cost-effective, and reliable method for sealing cables in walls, ensuring tight sealing and resistance to elevated temperatures without the risk of gasket failure.
Implementation Method 1
acting axially with a predetermined force F1, a part of the body is deformed, forming an outer ring on the connector body
Implementation Method 2
followed by radial crimping of the part of the body with the force F2
Implementation Method 3
Before the operation of radial crimping/clamping, a flexible seal, in which the cable is placed, is inserted into the through opening of the connector body
Data Source
AI summary
The object of the invention is a method and a connector for fixing a cable, especially an electrical one, in a wall of electronic, electrical, pneumatic, hydraulic and mechanical equipment. A method for attaching a cable, especially an electrical one, in a wall, characterised in that a profiled sleeve constituting a connector body (1) is seated in an opening in the wall (4), so that the abutment surface (2) of the body (1) abuts the wall (4), and subsequently, acting axially with a predetermined force F1, a part of the body (1) is deformed, forming an outer ring (7) on the connector body (1), in the vicinity of the housing wall (4), while a cable (6), especially an electrical one, is inserted into the through opening (3) of the connector body (1), followed by radial crimping of the part of the body (1) with the force F2. The method according to claim (1), characterised in that, before the operation of radial crimping/clamping, a flexible seal (8), in which the cable (6), especially an electrical one is placed, is inserted into the through opening (3) of the connector body (1). A connector for fixing/attaching cables, especially electrical ones, constituting a passage in a wall, characterised in that a profiled sleeve constituting the connector body (1) is seated in an opening in the wall (4) by means of a formed outer ring (7) and an abutment surface (2), in addition the connector body (1) comprising a through opening (3) in which a radially clamped in a part of the connector body (1) cable (6), especially an electrical one, is placed. The connector profiled body (1) has a thicker wall in the radially clamped part, than in the part deformed by axially applied forces.