Heat Shrink Sealing for Multi-Wire Terminals
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Solution Overview
Problem
Existing sealing systems for ring terminals with multi-wire configurations in the automotive industry face challenges in creating a reliable and cost-effective water-tight seal, as they are prone to water wicking and adhesive oozing, which interferes with metal-to-metal contact and is labor-intensive to implement.
Innovation Solution
A sealing system using a combination of heat shrinkable tubing and adhesive, where a high-viscosity adhesive is contained within a double-walled heat shrinkable tubing structure, with a low-viscosity adhesive flowing across the wires to create a seal, preventing adhesive contamination and ensuring effective electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external adhesive systems are used to seal multi-wire terminal configurations, then water-tight sealing is improved, but adhesive oozing occurs that interferes with metal-to-metal contact
Solution Approach 1:
The patent uses heat shrink tubing as a flexible shell structure that shrinks upon heating to form a tight seal around the terminal and wires. This containment structure prevents adhesive from oozing out while maintaining the water-tight seal, directly resolving the contradiction between sealing effectiveness and adhesive containment.
2Reliability
If multi-component multi-step sealing processes are used, then sealing reliability is improved, but manufacturing complexity and labor intensity increase
Solution Approach 1:
The patent combines multiple sealing functions into a single integrated system where heat shrink tubing and adhesive work together in one application step. The heat shrink tubing provides both the containment structure and the sealing function simultaneously, eliminating the need for separate application steps and reducing manufacturing complexity while maintaining sealing reliability.
3Object-affected harmful factors
If adhesive is applied to seal multiple wires, then water ingress prevention is improved, but adhesive contamination of terminal surfaces occurs
Solution Approach 1:
The patent employs a nested structure where the adhesive is contained within the heat shrink tubing, which in turn is applied over the terminal and wires. This nested arrangement allows the adhesive to perform its sealing function against water ingress while the heat shrink tubing prevents adhesive contamination of the terminal surfaces.
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 system provides a reliable, cost-effective, and simplified method for sealing multiple electrical wires, preventing water ingress and adhesive contamination, while maintaining effective electrical contact.
Implementation Method 1
Heat shrink tubing (HST) is a shrinkable plastic tube often used to insulate electrical wires. HST provides abrasion resistance and environmental sealing protection... As an HST recovers, i.e., shrinks, it exerts an inward force against the items it surrounds, which is referred to as the 'hoop stress' of the HST.
Implementation Method 2
Upon the application of heat to the device, the low-viscosity adhesive flows across and through the plurality of electrical wires
Data Source
AI summary
A system for sealing an electrical terminal which includes a device for sealing a plurality of electrical wires to a wire attachment portion of an electrical terminal. The device includes a shrinkable tubing which is placed over the plurality of electrical wires such that one end thereof extends over the wire attachment portion of the electrical terminal. A sealant/adhesive is placed within the heat shrink tubing and has a first portion proximate to the edge of heat shrink tubing. The sealant/adhesive has a strip of high viscosity sealant/adhesive proximate a strip of low viscosity sealant/adhesive. Upon the application of heat to the device after installation of the device over the electrical terminal, the shrinkable tubing starts to recover, the first portion of the sealant/adhesive flows and seals free ends of the plurality of electrical wires to seal the free ends of the electrical wires.