Molded Electric Wire Water-Stop via Soft Protrusion and Fixing Member
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Solution Overview
Problem
Existing molded portion-equipped electric wires face challenges in effectively preventing liquid ingress, such as water, between the molded portion and the insulating coating, particularly due to the difficulty in compressing and inserting a rubber stopper in a compressed state, which complicates the operation and may lead to increased component size.
Innovation Solution
The design incorporates a softer second molded portion that protrudes from the first molded portion and is pressed against the insulating coating by a harder fixing member, which is attached via a locking mechanism, allowing for easier suppression of liquid entry without the need for a compressed rubber stopper. This configuration includes a silicone resin for the second molded portion and insulating coating, enhancing attachment and flexibility, and an annular fixing member with assembled fixing pieces for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rubber stopper is inserted in a compressed state to achieve higher water-stopping property, then the water-stopping property is improved, but the ease of operation deteriorates due to the need for strong compression force and complex insertion process
Solution Approach 1:
The patent removes the rubber stopper component entirely from the system. Instead of inserting a separate rubber stopper, the insulating coating itself is designed to extend into the molded portion, forming an integrated water-stopping structure that eliminates the need for separate compression and insertion operations.
Solution Approach 2:
The patent merges the insulating coating and the water-stopping function into a single integrated structure. The insulating coating extends into the molded portion to form a water-stopping protrusion, combining the electrical insulation function and liquid barrier function into one component, thereby simplifying the overall structure and improving ease of manufacture.
2Reliability
If a rubber stopper is compressed and inserted to improve water-stopping property, then the reliability is improved, but the device complexity increases due to additional components and assembly steps
Solution Approach 1:
The patent extracts and eliminates the rubber stopper component from the water-stopping structure. The water-stopping function is achieved through the insulating coating extending into the molded portion, reducing the number of components and simplifying the overall device structure.
Solution Approach 2:
The patent combines the insulating coating and water-stopping protrusion into a single integrated component. This merging of functions reduces device complexity by eliminating separate parts and simplifying the assembly process while maintaining effective water-stopping capability.
3Ease of operation
If a softer second molded portion is used to improve ease of attachment, then the ease of operation is improved, but the hardness and structural strength deteriorates
Solution Approach 1:
The patent applies local quality by creating a softer region specifically at the water-stopping protrusion area of the insulating coating, while the rest of the insulating coating maintains its original hardness. This localized softening allows the protrusion to be compressed and attached easily to the molded portion, while the overall structural integrity of the insulating coating is preserved.
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 allows for more efficient and easier suppression of liquid entry between the molded portion and the insulating coating, reducing the complexity of the operation and potential size increase, while providing a stronger and more reliable water-stopping mechanism compared to traditional methods.
Implementation Method 1
a second molded portion that is formed integrally with the first molded portion, that is softer than the first molded portion, and that protrudes from the first molded portion toward the side opposite to a terminal side while being in contact with an outer circumferential surface of the insulating coating
Data Source
AI summary
A molded portion-equipped electric wire includes an insulated electric wire, a terminal connected to a core wire at an end of the insulated electric wire, a first molded portion covering a portion at which the terminal and the core wire of the insulated electric wire are connected to each other, a second molded portion that is formed integrally with the first molded portion, that is softer than the first molded portion, and that protrudes from the first molded portion toward the side opposite to the terminal side while being in contact with an outer circumferential surface of the insulating coating, and a fixing member that has an annular shape surrounding the second molded portion and that is attached to the first molded portion and the second molded portion in a state in which the fixing member presses the second molded portion against the outer circumferential surface of the insulating coating.