Epoxy Cable Seal Assembly to Block Moisture Wicking
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Solution Overview
Problem
Existing lighting fixtures face water intrusion issues through electrical conductors due to thermal expansion and contraction, leading to corrosion, safety hazards, and premature failure, especially in wet locations, and current sealing methods are inadequate for low-profile applications.
Innovation Solution
A waterproof seal system for electrical cables that involves exposing and solidifying electrical conductors within windows in the cable, using a covering with epoxy to prevent moisture ingress, and maintaining radial distance between conductors with spacers to prevent short-circuits, while minimizing the seal's axial length for compact designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealing methods (O-rings, gaskets) are used to seal electrical cables, then water intrusion is prevented, but the fixture profile increases and space is consumed
Solution Approach 1:
The patent combines the sealing function with the cable assembly itself by applying sealant directly to the conductors and insulation within the cable, eliminating the need for separate O-rings or gaskets. This integration achieves waterproofing without increasing fixture profile.
Solution Approach 2:
The patent removes traditional sealing components (O-rings, gaskets) from the assembly and replaces them with a sealant applied directly to the cable elements, extracting the bulk material requirements while maintaining the sealing function.
2Temperature
If thermal expansion and contraction are allowed to occur in sealed fixtures, then temperature regulation is maintained, but moisture is drawn into the fixture through electrical cables
Solution Approach 1:
The patent creates a continuous sealant barrier that remains effective throughout thermal expansion and contraction cycles, maintaining the water block while allowing the fixture to undergo normal thermal regulation without drawing moisture through the cable assembly.
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
Effectively prevents water from entering the light fixture through electrical cables without degrading the cable's current-carrying capacity, suitable for low-profile applications, and maintains the seal's integrity in wet conditions, reducing corrosion and extending fixture life.
Implementation Method 1
The epoxy material is provided such that it occupies spaces within the first and second windows and prevents water from wicking through the electrical cable
Implementation Method 2
The covering is provided such that it prevents moisture from penetrating into the electrical cable
Data Source
AI summary
A waterproof seal for electrical assemblies wherein an outer sheath of an electrical cable is removed to expose the wires and the insulation is removed from the wires to form a window of exposed electrical conductor, the electrical conductors being maintain apart from each other and contained in a cover that may comprise a connector, an epoxy applied to the electrical conductors to fill in all the space in and around the electrical conductors and the cover to form a waterproof seal that prevents water from wicking past the waterproof seal via an interior of the electrical cable.