Laser-Structured Cable Seal for Injection-Molded Electrical Components
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Solution Overview
Problem
Existing electrical components face challenges with reliability and safety due to issues like hidden corrosion and complex troubleshooting, especially in environments with moisture or vapors, where the connection between conductors and functional elements can lead to failure and risk, particularly in devices subject to varying temperatures and vibrations.
Innovation Solution
The electrical component features a plastic insulating sheath with a groove pattern created by laser machining, which forms a permanent seal with an injection-molded isolator housing, using a web pattern that anchors the housing to the sheath, preventing liquid ingress and reducing the risk of corrosion and failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If substance-to-substance bonding is used to join the isolator housing to the plastic insulating sheath, then the connection is achieved, but the sealing reliability deteriorates due to hidden corrosion and material incompatibility
Solution Approach 1:
The patent replaces the chemical bonding system (substance-to-substance bonding) with a mechanical interlocking system. The isolator housing features a geometric pattern of protrusions that engage with corresponding recesses in the plastic insulating sheath, creating a mechanical connection that is immune to corrosion and material incompatibility issues affecting chemical bonds.
Solution Approach 2:
The patent applies different joining mechanisms to different regions: the geometric pattern provides mechanical interlocking at critical sealing points, while the injection molding process ensures material integration in surrounding areas. This localized application of joining methods optimizes both manufacturability and sealing reliability.
2Adaptability or versatility
If the electrical component is used in environments with moisture and vapors, then the operational versatility is improved, but the reliability deteriorates due to hidden corrosion
Solution Approach 1:
The patent replaces chemical bonding with mechanical interlocking through geometric patterns, creating a corrosion-free connection. The protrusions and recesses form a physical barrier that prevents moisture and vapors from reaching the interface between the isolator housing and plastic insulating sheath, eliminating the root cause of hidden corrosion while maintaining environmental adaptability.
Solution Approach 2:
The geometric pattern creates a labyrinthine sealing structure that acts as a physical barrier against moisture and vapors. The interlocking protrusions and recesses form multiple sealing interfaces that prevent corrosive agents from penetrating to the conductor connections, enabling reliable operation in harsh environments.
3Manufacturing precision
If laser machining is used to create the groove pattern on the plastic insulating sheath, then the manufacturing precision is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent replaces complex mechanical machining operations with laser machining to create the groove pattern. The laser process directly writes the geometric pattern into the plastic insulating sheath with high precision, eliminating the need for multiple mechanical tooling steps, fixtures, and manual operations while maintaining tight tolerances for the interlocking features.
Solution Approach 2:
The patent uses laser machining parameters (power, speed, pulse duration) to precisely control the groove pattern geometry. By optimizing these parameters, the process achieves high manufacturing precision for the interlocking features while keeping the process itself relatively simple and integrated into the manufacturing flow.
4Productivity
If the isolator housing is injection-molded onto the cable, then the manufacturing productivity is improved, but the sealing reliability deteriorates without proper anchoring
Solution Approach 1:
The patent prepares the plastic insulating sheath in advance by laser-machining the groove pattern and creating the geometric recesses before the injection molding step. This preliminary action ensures that when the isolator housing is injection-molded, the geometric protrusions immediately engage with the pre-prepared recesses, providing both anchoring and sealing during the molding process itself, thus maintaining high productivity without compromising reliability.
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
This solution enhances the reliability and safety of electrical components by creating a long-lasting, impermeable seal that reduces the risk of corrosion and failure, even when using different materials for the sheath and housing, and simplifies troubleshooting and maintenance.
Implementation Method 1
the plastic insulating sheath of the cable is circumferentially structured on its outer surface, in the region of an annular zone covered by the isolator housing of the electrical functional unit, by means of laser machining
Implementation Method 2
the isolator housing and the plastic insulating sheath are sealed permanently relative to one another against liquid media in the annular zone
Data Source
AI summary
An electrical component has an electrical cable and an electrical functional unit undetachably connected at an end side. The electrical cable has a metallic conductor and a plastic insulating sleeve surrounding the conductor. The electrical functional unit has an insulator housing injection-molded onto the plastic insulating sleeve, and an electrical functional element accommodated in the insulator housing and with which contact is made by the conductor. The plastic insulating sleeve is in a ring zone covered by the insulator housing, structured on its outer surface in an encircling manner by laser processing with a groove pattern and raised portions between the grooves. The insulator housing has a pattern formed during injection-molding by the groove pattern of the insulating sleeve, having webs which enter grooves and are anchored such that the insulator housing and insulating sleeve are permanently sealed from one another in respect of liquid media in the ring zone.