Flexible Bulkhead Cable Penetration for Sealing and Cable Movement
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Solution Overview
Problem
Existing bulkhead pass-through systems for cables and pipes in motor vehicles face issues with movement limitations, sealing impairment, and maintenance challenges due to the rigidity introduced by polyurethane foam, which affects acoustic and sealing performance and complicates assembly.
Innovation Solution
A bulkhead pass-through system with a flexible holding structure that is removably mounted on both the support and counter-support, allowing for movement of cables and pipes without damage, and featuring a more flexible counter-support and holding structure made from elastomeric materials to enhance sealing and acoustic insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyurethane foam is used to secure the cable bundle in the bulkhead fitting, then the cable bundle is held firmly in place, but the cable bundle's movement is limited and damage may occur
Solution Approach 1:
The patent replaces rigid polyurethane foam with a flexible rubber sealing ring that can deform elastically. The sealing ring has a radial inner surface that flexibly contacts the cable bundle, allowing axial movement while maintaining secure holding and sealing. This flexible shell approach resolves the contradiction by providing both firm securing and movement capability.
Solution Approach 2:
The patent changes the material parameter from rigid polyurethane foam to elastic rubber material. This parameter change allows the sealing structure to deform under cable bundle movement while maintaining contact and sealing, thus enabling cable movement without compromising securing reliability.
2Reliability
If polyurethane foam is used to hold the cable harness, then the cable harness is secured, but the seal in the olive may be impaired and acoustic performance reduced
Solution Approach 1:
The rubber sealing ring acts as a flexible shell that maintains continuous elastic contact with the cable bundle and the olive surface. This flexible contact preserves the acoustic seal while allowing cable movement, unlike rigid foam that creates gaps when cables move.
Solution Approach 2:
The bulkhead fitting uses composite construction with a rigid support structure and a flexible rubber sealing component. This combination provides both structural integrity for securing and elastic compliance for maintaining acoustic seal during cable movement.
3Reliability
If polyurethane foam is used to secure the cable bundle, then the cable bundle is held firmly, but maintenance requires drilling the olive which leads to loss of properties and performance
Solution Approach 1:
The patent extracts the cable bundle from the rigid polyurethane foam matrix and places it in a flexible rubber sealing ring that can be independently removed. This allows the cable bundle to be extracted from the bulkhead fitting without damaging the olive or support structure, greatly simplifying maintenance.
Solution Approach 2:
The flexible rubber sealing ring provides dynamic adaptability during maintenance operations. It can deform to accommodate cable removal and reinstallation, and can be removed and reinstalled multiple times without compromising the structural integrity of the bulkhead fitting.
4Reliability
If significant rigidity is provided to the bulkhead due to polyurethane foam, then the cable harness is secured, but it becomes difficult to mount on a vehicle
Solution Approach 1:
The patent segments the bulkhead fitting into a rigid support structure and a separate flexible rubber sealing ring. This segmentation allows the rigid support to be mounted on the vehicle bulkhead, while the flexible sealing ring is installed separately to accommodate cables, simplifying the overall mounting process.
Solution Approach 2:
The flexible rubber sealing ring serves as a compliant element that can be installed after the rigid support is mounted. Its flexibility allows it to adapt to slight variations in installation conditions and cable positions, making the mounting process easier and more tolerant of manufacturing tolerances.
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 flexible holding structure protects cables and pipes from damage, maintains sealing and acoustic performance, and simplifies installation and maintenance by allowing for movement and deformation without compromising sealing or acoustic insulation.
Implementation Method 1
a holding structure (30) for the cable and/or pipe, more flexible than the support and the counter-support
Implementation Method 2
the counter-support and the holding structure are made of a material more flexible than the material of the support; the support is made of a thermoplastic material and the counter-support is made of an elastomeric thermoplastic material, a vulcanized elastomeric thermoplastic material or an elastomeric material
Data Source
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AI summary
A bulkhead fitting (100) for at least one cable and/or at least one hose intended to pass through a bulkhead (T) separating a passenger compartment from an engine compartment of a motor vehicle, said bulkhead fitting comprising a support (10) and a counter-support (20) mounted on the support such that the support (10) and the counter-support (20) can, in use, each be positioned opposite a surface (T1, T2) of the bulkhead (T). The bulkhead fitting comprising a retaining structure (30) for said cable and/or hose, more flexible than the support (10) and the counter-support (20), and which is also removably mounted on both the support (10) and the counter-support (20).