Self-Sealing Sign Pass-Through for Wire Protection and Wall Sealing
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Solution Overview
Problem
Existing exterior lighted signs, such as channel letter signs, face challenges in protecting power supply wires as they pass through openings in walls, which can lead to damage during installation and compromise insulation due to sharp edges and unfinished holes.
Innovation Solution
A pass-through apparatus featuring a flexible, self-sealing grommet and cylindrical conduit allows toolless coupling of power supplies to wall-affixed signs, accommodating varying wall thicknesses and providing inherent water-tight seals without the need for additional sealants or adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If supply wires pass through openings in the wall and sign enclosure, then power can be delivered to the light sources, but the wires are damaged by sharp edges and unfinished surfaces
Solution Approach 1:
A grommet is introduced as an intermediary component between the supply wire and the opening in the sign enclosure. The grommet provides a smooth, protected passage for the wire while being installed in the opening, thus preventing direct contact between the wire and sharp edges. This mediator resolves the contradiction by eliminating the harmful effect of sharp edges on wire reliability.
Solution Approach 2:
The grommet is pre-installed in the opening before the supply wire is routed through it. This beforehand cushioning provides protective coverage for the wire path in advance, preventing potential damage from sharp edges before the wire is even installed. The protective function is established prior to the wire's exposure to harmful factors.
2Ease of operation
If holes are drilled through the wall for wire passage, then power supply is enabled, but the holes have unfinished quality that damages wire insulation
Solution Approach 1:
The grommet serves as an intermediary between the unfinished hole in the wall and the supply wire. It provides a finished, smooth interior surface that the wire contacts, while the exterior of the grommet interfaces with the rough hole edges. This mediator enables easy wire installation through the hole while preventing insulation damage from the unfinished hole surfaces.
3Adaptability or versatility
If the grommet is made flexible to accommodate wall thickness variations, then adaptability is improved, but structural strength is reduced
Solution Approach 1:
The grommet is constructed from flexible material that can deform to accommodate variations in wall thickness. This flexibility allows the grommet to adapt to different installation conditions while maintaining sufficient structural strength through the material's elastic properties and geometric design. The flexible shell conforms to the wall surface while providing adequate support for wire passage.
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 effectively protects power supply wires from damage and ensures a secure, water-tight seal between the inside and outside environments, facilitating easy installation and maintaining the integrity of the sign's insulation.
Implementation Method 1
The grommet provides inherent, water tight seals that isolate the interior of the sign and the inside environment, where the power supply is located, from the outside environment.
Data Source
AI summary
A disclosed pass-through apparatus suitable for use in a lighting assembly includes a cylindrical conduit and a flexible, self-sealing grommet. The cylindrical conduit has a length suitable for extending from a first position within an inside environment on a first side of a wall, through a hole in a wall to an outside environment. The flexible grommet defines a cylindrical channel extending a length of the grommet, from a first end of the grommet to a second end. The conduit extends through the channel and the grommet is positionable at any of a plurality of positions along the length of the grommet. The grommet defines an annular groove, formed in an outer diameter of the grommet, at the intermediate position. The annular groove is sized to engage an opening in a panel of the lighting assembly located in the outside environment.