Overmolded Cable Bushing With Conical Seal Receptacle
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Solution Overview
Problem
Existing cable bushing solutions for sealing cables in housing walls are complex, costly, and require multiple production steps, often failing to provide a secure and efficient seal against dust, moisture, and accidental cable removal.
Innovation Solution
A one-piece cable bushing design featuring a conically tapered seal receptacle overmolded onto the cable sheath, with a U-shaped radial recess and multiple circumferential sealing lips, allowing for easy installation and secure sealing, and optionally using different hardness materials for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components (seal, bushing, retaining features) are used to seal a cable in a housing wall, then the sealing reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the seal, bushing, and retaining features into a single integrated cable bushing component. The seal element is positioned within a recess of the bushing body, while radial flanges and axial shoulders are formed as integral parts of the same structure. This merging eliminates the need for multiple separate components while maintaining effective sealing and cable retention functions.
2Reliability
If multiple separate components are used to seal a cable, then the sealing effect is improved, but the manufacturing cost and production steps increase
Solution Approach 1:
The cable bushing integrates the seal, bushing body, and retaining features into a single component that can be manufactured in one production process. This eliminates the need for multiple assembly steps and reduces manufacturing complexity, thereby lowering production costs while maintaining effective sealing performance.
3Reliability
If a complex multi-component system is used to seal cables, then the sealing performance is improved, but the storage costs and handling complexity increase
Solution Approach 1:
The patent consolidates multiple separate components (seal, bushing, retaining features) into a single integrated cable bushing. This reduction in component quantity simplifies inventory management, reduces storage space requirements, and eliminates the need for complex assembly procedures, while still delivering effective sealing performance.
4Reliability
If conventional sealing solutions are used, then cable sealing is achieved, but the installation process becomes complex and time-consuming
Solution Approach 1:
The integrated cable bushing design combines the seal element and mounting features into a single pre-assembled unit. The seal is positioned within a recess of the bushing body, and the radial flanges and axial shoulders are formed as integral parts, allowing the entire assembly to be installed as one component rather than requiring separate installation of multiple parts.
5Reliability
If conventional sealing solutions with multiple components are used, then sealing is achieved, but the production time and efficiency decrease
Solution Approach 1:
The cable bushing integrates the seal, bushing body, and retaining features into a single component that can be manufactured in one production process. This eliminates the need for multiple assembly steps and reduces manufacturing complexity, thereby lowering production costs while maintaining effective sealing performance.
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 design achieves a cost-effective, efficient seal that is self-locking and adaptable to various diameters, ensuring effective sealing and protection against dust, moisture, and accidental cable removal, while simplifying manufacturing and reducing component counts.
Implementation Method 1
at least the seal receptacle being formed or overmolding on the cable sheath
Implementation Method 2
By exerting pressure on the seal receptacle in the direction of the opening in the housing wall, a secure hold of the seal receptacle or the seal within the opening can be achieved
Data Source
Figure 1~2
AI summary
The invention relates to a cable gland for passing a cable through an opening in a wall, in particular a housing wall, comprising a cable with a cable sheath, a sealing receptacle radially surrounding the cable sheath and a seal arranged in the sealing receptacle, wherein at least the sealing receptacle is formed by injection molding or overmolding onto the cable sheath.