Multi-Core Cable Seal Structure Using Rubber Plugs
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Solution Overview
Problem
Conventional seal structures for multi-core cables, which use hot-melt resin, are time-consuming and inefficient, affecting operation efficiency and increasing manufacturing costs.
Innovation Solution
A seal structure comprising a sheath rubber plug and electrical wire rubber plugs fitted into a housing, with a cap to retain the plugs, allowing for quicker assembly and reduced component count, enabling faster construction and lower costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hot-melt resin is used for sealing, then waterproofing is achieved, but construction time increases and operation efficiency decreases
Solution Approach 1:
The patent extracts the sealing function from the hot-melt resin process and implements it through pre-formed rubber plugs with integrated sealing structures. The sealing function is separated into discrete components (sheath rubber plug, electrical wire rubber plug) that can be installed without thermal processing, eliminating the time-consuming heating and cooling cycles while maintaining waterproofing effectiveness.
Solution Approach 2:
The patent replaces the thermal field (heating and melting process) with a mechanical field (physical insertion and compression of rubber plugs). The sealing action is achieved through mechanical compression of the rubber material against the cable and housing interfaces, substituting the thermal processing system with a purely mechanical installation system that significantly reduces construction time.
2Reliability
If hot-melt resin process is used, then sealing is achieved, but manufacturing cost increases
Solution Approach 1:
The sealing components (rubber plugs) are pre-formed and pre-configured with integrated sealing structures before installation. The sheath rubber plug and electrical wire rubber plug are manufactured as ready-to-install components with built-in sealing features, eliminating the need for on-site heating, melting, and processing operations, thereby reducing manufacturing complexity and cost.
Solution Approach 2:
The patent changes the material state parameter from thermoplastic (hot-melt resin requiring temperature changes) to elastomeric (rubber material that functions at ambient temperature). This parameter change eliminates the need for thermal processing equipment and energy consumption, simplifying the manufacturing process and reducing overall manufacturing costs while maintaining sealing effectiveness.
3Productivity
If assembly format is used with rubber plugs, then construction time is reduced, but sealing effectiveness must be maintained
Solution Approach 1:
The patent employs a nested structure where the electrical wire rubber plug is inserted into the sheath rubber plug, and both are fitted into the housing. This nested arrangement ensures that sealing is achieved at multiple levels (electrical wire level and sheath level) simultaneously, maintaining comprehensive sealing effectiveness while enabling rapid assembly through a single insertion motion.
Solution Approach 2:
The patent utilizes rubber plugs with flexible, elastic properties that can deform during installation and then recover to maintain constant sealing pressure. The flexible rubber material adapts to the cable and housing interfaces, ensuring reliable sealing effectiveness while allowing for simple, tool-free installation that significantly reduces construction time.
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 proposed seal structure significantly reduces construction time and manufacturing costs while ensuring effective sealing of multi-core cable terminals and electrical wires, improving operational efficiency.
Implementation Method 1
If setting is performed such that the electrical wire rubber plug is compressed in the axial direction when the cap is attached, it is possible to increase the contact pressure applied to the electrical wires
Implementation Method 2
a sheath rubber plug that is fitted around a terminal of the sheath; an electrical wire rubber plug through which the electrical wires individually pass
Data Source
AI summary
A multi-core cable in which electrical wires are enveloped by a sheath, a sheath rubber plug that is fitted around the terminal of the sheath, an electrical wire rubber plug through which the electrical wires, which extend from the terminal of the sheath, individually pass, and a housing that has attachment holes into which the sheath rubber plug and the electrical wire rubber plug are respectively fitted.