Polyurethane Cable Sealing Ring Fusion Bond
Solution Overview
Problem
The sealing function of cable bushing seals in existing connector housings deteriorates over time, necessitating an improvement in sealing effectiveness.
Innovation Solution
A sealing ring is introduced in a form-fitting manner into the contour of the inner housing part and melt-connected to the outer housing part during the encapsulation process, utilizing a polyurethane plastic that reacts between 60° and 95°C to form a stable fusion bond, potentially incorporating a labyrinth structure and foam material for enhanced sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a labyrinth seal is installed in the cable bushing, then the sealing function is provided, but the sealing function decreases over time
Solution Approach 1:
The patent changes the material parameters of the sealing ring from traditional rubber to polyurethane plastic, which exhibits superior aging resistance and maintains its sealing properties over time. This material parameter change resolves the contradiction by providing both initial sealing effectiveness and long-term durability without the degradation issues of conventional materials.
Solution Approach 2:
The patent creates a composite structure by melt-connecting the polyurethane sealing ring to the outer housing part during encapsulation. This composite approach combines the sealing capabilities of the ring with the structural integrity of the housing, resulting in a durable assembly that maintains sealing function throughout the service life while resisting scratches and breaks.
2Reliability
If the sealing ring is melt-connected to the outer housing part, then the stability and durability of the seal is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent merges the sealing ring installation and outer housing formation into a single encapsulation process. The polyurethane sealing ring is introduced in a form-fitting contour and melt-connected to the outer housing part during the same manufacturing operation, eliminating separate assembly steps and reducing overall process complexity while ensuring a stable, integrated connection.
Solution Approach 2:
The patent utilizes the phase transition of polyurethane material during the encapsulation process. The material transitions from a moldable state to a hardened state, creating a permanent melt-connection between the sealing ring and outer housing. This phase change approach simplifies manufacturing by eliminating the need for separate bonding operations while ensuring robust mechanical attachment.
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 provides a stable and long-lasting seal that is resistant to scratches and breaks, adaptable to various cable diameters, and promotes chemical crosslinking, ensuring effective cable protection and reduced gas inclusions for improved performance.
Implementation Method 1
the sealing ring is introduced in a form-fitting manner in a contour of the inner housing part and the sealing ring is melt-connected to the outer housing part
Implementation Method 2
covalent bonds between the connection partners can also arise as a result of chemical crosslinking
Implementation Method 3
utilizing a polyurethane plastic that reacts between 60° and 95°C to form a stable fusion bond
Implementation Method 4
potentially incorporating a labyrinth structure and foam material for enhanced sealing
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a plug-in connector housing comprising an inner housing part (1) and an outer housing part (2). The inner housing part (1) forms a hollow space, inside which electrical components and electrical connecting elements are arranged. The outer housing part (2) is formed in a casting process and encloses the inner housing part (1). The inner housing part (1) comprises a lead-through (9) for connecting a cable (6), a sealing ring (7) being disposed between the cable (6) and the lead-through (9). According to the invention, the sealing ring (7) is introduced in a form-fitting manner into a contour (8) of the inner housing part (1) and is fused to the outer housing part and a cable strain relief device.