Heating Cable End Cap Air Evacuation Seal
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Solution Overview
Problem
Existing solutions for sealing heating cable end portions are prone to air bubbles, leading to water ingress and production rejects due to inadequate sealing and air entrapment.
Innovation Solution
A heat shrinkable tube with an evacuation and seal-off portion is used, featuring an entrance opening for the cable, an outlet for air evacuation, and a hot melt adhesive layer, where exposure to shrinking temperature and pressure force ensures air evacuation and gap filling, minimizing air bubbles and ensuring a watertight seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive agent is used to fill gaps between wires and heat shrinkable tube is heated to melt the adhesive, then a watertight construction is achieved, but air bubbles are entrapped in the seal off leading to water ingress
Solution Approach 1:
The patent introduces a preliminary air evacuation step before the adhesive sets. The heat shrinkable tube includes an evacuation portion with an outlet opening that allows air to escape during the heating process, preventing air bubble entrapment while the adhesive is being melted and filling gaps
Solution Approach 2:
The patent extracts the harmful air bubbles from the sealing system by providing a dedicated evacuation pathway. The outlet opening in the evacuation portion allows air to be removed from the sealing structure during the adhesive curing process, eliminating the source of potential water ingress
2Object-affected harmful factors
If heat shrinkable tube is used to cover and seal the heating cable end portion, then protection from harsh environment is provided, but air bubbles are trapped leading to sealing failures
Solution Approach 1:
The patent incorporates an air evacuation mechanism that operates during the heat shrinking process. Before the adhesive fully sets and creates a permanent seal, air is evacuated through the outlet opening, ensuring the sealing structure is free of air bubbles that would compromise its integrity
Solution Approach 2:
The evacuation portion acts as an intermediary element between the sealed environment and the external atmosphere. It provides a controlled pathway for air to escape during the sealing process, mediating between the need for a tight seal and the need to eliminate air bubbles
3Reliability
If adhesive is applied to fill clearances between conductors, then electrical connection protection is improved, but the complexity of obtaining satisfying filling increases production rejects
Solution Approach 1:
The patent employs a self-leveling adhesive material that automatically fills gaps and clearances between conductors when heated. The adhesive flows on its own to achieve complete filling without requiring complex application equipment or manual intervention, simplifying the manufacturing process
Solution Approach 2:
The patent utilizes the temperature-dependent viscosity changes of the adhesive material. When heated during the heat shrink process, the adhesive transitions to a lower viscosity state that enables it to flow and fill all gaps between conductors automatically, then solidifies to provide 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 effectively prevents air bubbles and ensures a reliable, watertight seal for heating cable end portions, reducing production rejects and water ingress, by using a heat shrinkable tube with a built-in air evacuation mechanism and hot melt adhesive for comprehensive sealing.
Implementation Method 1
exposure to a shrinking temperature and to a subsequent pressure force allows the shrinkage and forming of the heat shrinkable tube about the heating cable end portion
Implementation Method 2
A heat shrinkable tube with an evacuation and seal-off portion is used, featuring an entrance opening for the cable, an outlet for air evacuation, and a hot melt adhesive layer
Data Source
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AI summary
The invention concerns an end cap arrangement (1) for sealing off an end portion (3) of a heating cable (2) comprising at least two conductors (4, 5) that are electrically connected. The end cap arrangement (1) comprises a heat shrinkable tube (22, 22a) having an entrance opening (30) for receiving the heating cable end portion, and an outlet opening (26) for evacuation of air. The exposure to a shrinking temperature tshrink and to a subsequent pressure force (F) allows the shrinkage and forming of the heat shrinkable tube (22, 22a) about the heating cable end portion and the evacuation of air from the outlet opening (26). The invention also concerns a method for installing an end cap arrangement.