Fuse Box Cable Seal With Dynamic Insert for IP69 Protection
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Solution Overview
Problem
Manufacturing a fuse box that meets IP67 and IP69K Ingress Protection ratings is challenging due to the need for accessing fuses during maintenance, preventing permanent sealing.
Innovation Solution
A seal comprising a plastic body and a rubber insert, designed with an outside structure that remains stationary and an inside structure that elongates and compresses to accommodate cable movement, providing a water-tight seal that maintains IP69 protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fuse box is permanently sealed to achieve IP67/IP69K protection, then water and dust ingress is prevented, but fuse accessibility for maintenance is lost
Solution Approach 1:
The fuse box is divided into a sealed housing containing the fuses and an accessible cover that can be removed. The seal assembly is segmented into a stationary outside structure and a movable inside structure, allowing the seal to maintain IP69K protection while accommodating cable movement and enabling fuse access through cover removal.
Solution Approach 2:
The seal assembly acts as an intermediary between the sealed housing and the external environment. It provides a water-tight barrier while allowing controlled interaction through the movable inside structure that accommodates cable movement, thus maintaining protection without completely isolating the fuses.
2Reliability
If a rigid seal is used to ensure water-tight protection, then ingress protection is maintained, but cable movement is restricted
Solution Approach 1:
The seal transitions from a static rigid structure to a dynamic system with a stationary outside structure and a movable inside structure. The movable inside structure can elongate and compress to accommodate cable movement while maintaining the water-tight seal, enabling the seal to adapt to varying cable positions and movements.
Solution Approach 2:
The seal's physical parameters are changed by allowing the inside structure to vary in length through elongation and compression. This enables the seal to maintain its water-tight function while adapting to different cable positions and movements, providing both protection and flexibility.
3Ease of manufacture
If a single-material seal is used, then manufacturing is simplified, but adaptability to different cable sizes is reduced
Solution Approach 1:
The seal is constructed as a composite assembly with a stationary outside structure and a movable inside structure made of different materials with complementary properties. This composite design allows the seal to accommodate various cable sizes while maintaining manufacturability, as each structure can be optimized for its specific function.
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
Ensures IP69 protection against dust and high-pressure, high-temperature water ingress, even with cable movement, and supports various cable sizes, enhancing durability and ease of use.
Implementation Method 1
The inside structure of the rubber insert moves in response to movement of the cable while the outside structure does not move. The inside structure simultaneously elongates and compresses in response to movement of the cable.
Implementation Method 2
The seal fits into the opening and holds the cable against the housing and prevents ingress of water or dust into the housing. The overmolded combination provides IP69 protection against high-pressure, high-temperature water ingress.
Data Source
AI summary
A seal for securing a cable to a fuse box includes a plastic body and a rubber insert. The plastic body has a receiving cavity along an inner surface. The rubber insert features an outside structure to join with the inner surface of the plastic body, an inside structure to surround the cable, and a fitting rib along an outside surface of the outside structure, the fitting rib to occupy the receiving cavity. The inside structure of the rubber insert moves in response to movement of the cable while the outside structure does not move.