Relay Conductor Sealing Member for Wire Terminal Liquid Penetration
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Solution Overview
Problem
Existing terminal-equipped wires face inefficiencies in manufacturing due to the need for removing insulation coatings and curing water sealants, leading to poor work efficiency and productivity, especially when exposed to liquids that can penetrate through capillary phenomena.
Innovation Solution
A terminal-equipped wire design featuring a relay conductor with a sealing member on its outer periphery, which prevents liquid penetration by closing clearances between the relay conductor and the insertion hole, eliminating the need for intermediate insulation coating removal and curing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water sealant is filled between the strands of the core exposed portion and covered by a waterproof sheet, then liquid penetration is prevented, but manufacturing complexity and labor-hours increase
Solution Approach 1:
The invention extracts the sealing function from the complex multi-step process (insulation removal, sealant filling, waterproof sheet covering) and integrates it into the relay conductor itself through the sealing member. The sealing member is formed as an integral part of the relay conductor, eliminating the need for separate sealing operations and reducing manufacturing complexity while maintaining liquid penetration prevention.
Solution Approach 2:
The sealing member is merged with the relay conductor to form an integrated structure. The sealing member is formed by extruding resin around the relay conductor in a single operation, combining the electrical connection function and the sealing function into one unified component, thereby reducing the number of manufacturing steps.
2Reliability
If insulation coating is removed at an intermediate position to form core exposed portion, then liquid sealant can be applied, but work efficiency decreases
Solution Approach 1:
The invention eliminates the need for insulation coating removal by extracting the sealing function and implementing it through the sealing member that is formed by extruding resin around the relay conductor. This approach removes the problematic step of insulation removal entirely while maintaining effective sealing.
Solution Approach 2:
The sealing member is formed by extruding resin around the relay conductor before final assembly, performing the sealing action in advance during the conductor formation process itself. This preliminary sealing action eliminates the need for subsequent insulation removal and sealant application steps.
3Reliability
If multiple operations (curing sealant, covering with waterproof sheet) are performed after sealant filling, then liquid penetration is prevented, but productivity is reduced
Solution Approach 1:
The sealing member is formed by extruding resin around the relay conductor in a single integrated operation, merging the sealing function with the conductor formation process. This eliminates the need for separate curing and waterproof sheet covering operations, significantly improving productivity while maintaining reliable liquid penetration prevention.
Solution Approach 2:
The sealing member is formed preliminarily during the relay conductor manufacturing process by extruding resin around it. This preliminary formation of the sealing member incorporates the sealing function into the base manufacturing process, eliminating the need for subsequent curing and covering operations.
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 design enhances work efficiency and productivity by preventing liquid intrusion into the connector terminal while maintaining electrical connectivity, reducing the number of manufacturing processes and improving the overall production efficiency.
Implementation Method 1
Liquid, such as oil or water, can penetrate between the conductors of the wire from an end part of the wire on an electronic device side in the terminal-equipped wire, and this liquid, can penetrate to the end part of the wire on the connector terminal side by a capillary phenomenon.
Data Source
AI summary
A terminal-equipped wire (1) includes a connector terminal (2), a wire (3), a relay conductor (4) and a sealing member (5). The connector terminal (2) is arranged in an insertion hole (71) provided in a connector case (7). The wire (3) is formed by bundling a plurality of conductors (31). The relay conductor (4) is composed of one conductor and electrically connects the connector terminal (2) and the wire (3). The sealing member (5) is mounted on the outer periphery of the relay conductor (4) and arranged in the insertion hole (71) to close a clearance (S1) between the inner periphery of the sealing member (5) and the outer periphery of the relay conductor (4) and a clearance (S2) between the outer periphery of the sealing member (5) and the inner periphery of the insertion hole (71).