Moulded Casting Seals Cable Core and Sheath
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Solution Overview
Problem
Existing electrical devices and connectors are vulnerable to water penetration through cable bushings, despite insulating sheaths, due to capillary forces and openings, which can lead to corrosion and functional disturbances.
Innovation Solution
An electrical device with a moulded casting that seals both the insulating sheath and the electrically conducting core of an electric cable, creating a comprehensive damp barrier by penetrating and sealing along specific lengths, and optionally connecting to a casing for enhanced protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a moulded casting penetrates and seals against both the insulating sheath and the electrically conducting core, then damp-proof protection is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The sealing process is divided into two distinct sections: an outer section (L3) where the moulded casting seals against the insulating sheath, and an inner section (L2) where it penetrates to seal against the electrically conducting core. This segmentation allows each sealing action to be optimized independently while achieving comprehensive damp-proof protection.
Solution Approach 2:
The insulating sheath is pre-compressed around the core before the moulded casting is applied. This preliminary compression creates a tighter fit and prepares the interface for effective sealing, ensuring that when the moulded casting is arranged, it can achieve reliable seals at both the outer sheath interface and the inner core interface.
2Reliability
If the insulating sheath is compressed around the core, then sealing effectiveness is improved, but the risk of damaging the core increases
Solution Approach 1:
The insulating sheath is compressed around the core in a controlled preliminary step before the moulded casting is applied. This staged approach allows the sheath to be pre-formed and stabilized, distributing the compression forces evenly and preventing sudden or excessive forces that could damage the core.
Solution Approach 2:
The moulded casting acts as a cushioning element that is arranged after the sheath compression. It provides a protective layer that absorbs and distributes any residual stresses, preventing direct transmission of damaging forces to the electrically conducting core while maintaining the compressed state of the sheath for effective sealing.
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 moisture penetration along the electric cable, ensuring the device remains damp-proof and protecting both the insulating sheath and conducting core from water ingress, thereby maintaining the integrity and functionality of the electrical components.
Implementation Method 1
the insulating sheath is pre-treated by the application of heat and pressure around the insulating sheath in order to make the insulating sheath penetrate into the space around the core
Implementation Method 2
A moulded casting is arranged around the electric cable in a section along the electric cable of a length L1 and seals against the insulating sheath
Implementation Method 3
the moulded casting of the insulating sheath penetrates and seals against the electrically conducting core in an inner section of a length L2 along the electric cable, wherein the electrical device is damp proof
Data Source
Figure 1~2
Figure 3~5
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AI summary
The present invention relates to an electrical device (5) including an electric cable (1) with an electrically conducting core (3) enclosed by an insulating sheath (2). A moulded casting (4) is arranged around the electric cable (1) in a section along the electric cable of a length (LI) and seals against the insulating sheath (2) in at least a first outer section of a length (L3) along the electric cable (1). The moulded casting (4) or the insulating sheath (2) penetrates and seals against the electrically conducting core (3) in a inner section of a length (L2) along the electric cable (1), wherein the electrical device (5) is damp proof along the electric cable (1). The invention also relates to a method of producing such an electrical device.