Expandable Sealant for Wire Connector Waterproofing
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Solution Overview
Problem
Existing methods for waterproofing electrical connections often fail to adequately protect the connections due to insufficient sealant viscosity and gravitational forces, leading to gaps that can result in electrical failure.
Innovation Solution
A two-phase expandable electrically insulative sealant is delivered in an unexpanded state to the interior chamber of a wire connector after the electrical junction is formed, which undergoes a phase change to generate internal expansion forces, encapsulating the junction and filling gaps, providing enhanced isolation and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealant methods are used to waterproof electrical connections, then the sealing process is simple, but the sealant cannot adequately cover the electrical connection due to insufficient viscosity and gravitational forces, resulting in gaps and potential electrical failure
Solution Approach 1:
The patent changes the physical state parameter of the sealant from liquid to expandable foam. The sealant is introduced in an unexpanded liquid state for easy delivery, then undergoes phase change to expand and fill the connector interior, eliminating gaps and ensuring complete coverage of electrical connections without requiring complex high-viscosity sealants or additional delivery mechanisms
Solution Approach 2:
The patent utilizes phase transition of the sealant material from liquid to expanded foam state. The sealant is delivered in liquid form through a simple port, then expands in situ to fill the connector housing and encapsulate electrical connections. This phase transition provides the necessary volume expansion and sealing pressure automatically, resolving the contradiction between simple delivery and effective sealing
2Ease of operation
If the sealant is delivered in unexpanded state, then the delivery process is simplified, but the sealant volume is insufficient to provide complete coverage until expansion occurs
Solution Approach 1:
The sealant material undergoes phase transition from compact liquid state during delivery to expanded foam state after introduction. This allows the sealant to be delivered in a small volume in unexpanded liquid form through simple ports, then automatically expands to fill the entire connector interior and provide sufficient coverage volume without requiring complex delivery systems or pre-calculated sealant quantities
3Adaptability or versatility
If the electrical connection configuration prevents sealant coverage, then various connection types can be made, but the sealant cannot reach all areas due to gravitational forces and viscosity limitations
Solution Approach 1:
The sealant expands in situ after introduction to the connector, transforming from liquid to expanded foam that flows into and fills all available spaces regardless of electrical connection configuration. This expansion process overcomes gravitational forces and viscosity limitations, ensuring complete coverage of complex wire arrangements, junctions, and connector interiors while maintaining adaptability to various electrical connection types
Solution Approach 2:
The sealant expansion process effectively segments the connector interior into sealed zones, with the expanding foam adapting to fill all cavities and spaces around electrical connections. This segmentation approach ensures that regardless of the complexity of the electrical connection configuration, the sealant divides and conquers the space to provide complete encapsulation and protection
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 ensures a robust, waterproof, and electrically insulative covering around the electrical connection, preventing accidental contact and environmental exposure, while also providing a cushion against external forces.
Implementation Method 1
an electrically insulative expandable sealant, which is delivered in an unexpanded state, into an interior chamber of a wire connector after the formation of an electrical junction in the wire connector. The electrically insulative expandable sealant in a first unexpanded state and typically a liquid state is delivered to a region proximate an electrical junction where a phase change occurs through an in situ internal expansion
Data Source
AI summary
A wire connector kit and a method of protecting an electrical connection comprising a wire connector and a source of expandable sealant wherein the expandable sealant is injected into a wire connector after the electrical connection has been formed with the expandable sealant undergoing an in situ internal expansion from a site proximate the electrical connection to encapsulate and protect the electrical junction from the environment or through forming a sealant plug in a housing through an in situ expansion of the sealant plug to protect an electrical connection cocooned within the housing by the sealant plug.