Sealing Reducing Washer Elastomeric Rim Toroid Seal
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Solution Overview
Problem
Existing metallic reducing washers fail to provide a weathertight seal when used in outdoor electrical enclosures, despite their ability to create a mechanical and electrical fit between smaller conduits or raceways and larger knockout holes, leading to water intrusion issues.
Innovation Solution
A sealing reducing washer with a metallic core and a pliable rim and toroid made from elastomer materials, such as silicone, that forms a weathertight seal by deforming to fit around the enclosure and conduit threads, ensuring a secure mechanical and electrical connection while preventing water intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional metallic reducing washers are used to provide mechanical and electrical connection, then the mechanical fit and electrical bonding are achieved, but the ability to provide a weathertight seal is lost
Solution Approach 1:
The reducing washer combines a metallic core (steel or aluminum) with an elastomeric sealing material to create a composite structure. The metal provides mechanical strength and electrical conductivity, while the elastomer provides weatherproofing and sealing capabilities, thus resolving the contradiction between mechanical/electrical connection reliability and protection against water intrusion
Solution Approach 2:
Different regions of the reducing washer have different properties: the central opening and inner surface maintain metallic characteristics for electrical bonding, while the outer rim and sealing surfaces are covered with elastomeric material for weatherproofing. This local differentiation allows simultaneous achievement of electrical connection and water sealing
2Object-affected harmful factors
If sealing materials like silicone sealers are added to metallic reducing washers, then water intrusion is attempted to be prevented, but the design complexity and installation difficulty increase
Solution Approach 1:
The sealing function is merged directly into the reducing washer body by overmolding the elastomeric material onto the metallic core. This integration eliminates the need for separate sealing components and simplifies installation, as the seal is inherently part of the washer itself rather than an add-on component
Solution Approach 2:
The elastomeric material inherently provides sealing functionality through its compliance and ability to deform, eliminating the need for additional sealing steps or materials. The washer self-seals upon installation as the elastomer conforms to the conduit and enclosure surfaces
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 sealing reducing washer effectively provides a weathertight seal between electrical enclosures and conduits or raceways, ensuring a secure and watertight connection even in outdoor environments, addressing the water intrusion issue.
Implementation Method 1
a pliable rim secured over the outer periphery of the metallic reducing washer, a portion of the rim circumferentially depending below the rear surface of the metallic reducing washer adjacent the outer periphery of the metallic reducing washer so as to form a weathertight seal against a surface of an electrical enclosure
Data Source
AI summary
A sealing reducing washer is formed from a metallic reducing washer having a front surface, a rear surface, an outer periphery, and an inner periphery with a pliable rim secured over the outer periphery of the metallic reducing washer, a portion of the rim circumferentially depending below the rear surface of the metallic reducing washer adjacent the outer periphery of the metallic reducing washer so as to form a weathertight seal against a surface of an electrical enclosure when the sealing reducing washer is secured to the enclosure, and a pliable toroid circumferentially positioned adjacent the inner periphery of the metallic reducing washer and extending circumferentially above the front surface of the metallic reducing washer in the region adjacent the inner periphery of the metallic reducing washer, the toroid dimensioned to form a weathertight seal with an electrical conduit or raceway.