Elliptical Sealing Rib for Rectangular Terminal Cable Seals
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Solution Overview
Problem
Cable holes in seals designed for low-hardness silicone materials face issues with high hardness and poor toughness in oil-resistant environments, leading to excessive force required for terminal insertion and reduced sealing performance when rectangular-section terminals are used, which is exacerbated by increasing the inner diameter to maintain interference fit, resulting in reduced sealing ability.
Innovation Solution
A seal with an elastic body featuring an elliptical inner contour line for the inner sealing rib that matches the major and minor sides of a rectangular terminal, ensuring an interference fit while preventing damage, combined with outer sealing ribs for additional sealing, forming a one-piece injection molded part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If oil-resistant materials are used for the seal, then oil resistance is improved, but hardness increases and toughness deteriorates, making terminal insertion difficult
Solution Approach 1:
The seal structure incorporates different regions with different functional properties: the main body uses hard oil-resistant material for durability, while the inner sealing rib provides localized flexibility and elasticity to facilitate terminal insertion and maintain sealing pressure
Solution Approach 2:
The seal combines hard oil-resistant material with elastic sealing components to create a composite structure that exhibits both oil resistance and operational flexibility, resolving the contradiction between material hardness and insertion ease
2Ease of operation
If the inner diameter of cable holes is increased to reduce insertion force, then terminal insertion becomes easier, but interference fit and contact pressure decrease, reducing sealing performance
Solution Approach 1:
The seal structure separates the cable receiving function from the sealing function: the cable hole provides mechanical support and guidance, while the inner sealing rib provides the interference fit and sealing pressure, allowing each component to be optimized independently
Solution Approach 2:
The sealing mechanism transitions from relying solely on cable hole interference fit to utilizing the inner sealing rib that extends into the cable hole, adding a new dimensional element for achieving sealing pressure without increasing overall hole diameter
3Ease of manufacture
If rectangular-section terminals are inserted into circular cable holes, then terminal connection is achieved, but major sides of terminals scrape the edges, leading to poor sealing
Solution Approach 1:
The cable hole cross-section changes from circular to rectangular to match the terminal shape, eliminating the scraping issue caused by geometric mismatch and ensuring proper alignment and sealing contact between the terminal and seal structure
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 improved sealing performance and reliability by maintaining interference fit and guiding terminal insertion, while ensuring compatibility with rectangular-section terminals and enhancing contact pressure.
Implementation Method 1
an inner sealing rib extending circumferentially around the through hole and interference fit with the cable to form a seal with the cable
Implementation Method 2
an elastic body having a through hole receiving a terminal with a cable
Data Source
AI summary
A seal includes an elastic body having a through hole receiving a terminal with a cable and an inner sealing rib extending circumferentially around the through hole and interference fit with the cable to form a seal with the cable. An inner contour line of the inner sealing rib is elliptical. A major axis and a minor axis of the inner contour line respectively correspond to a major side and a minor side of a rectangular section of the terminal.