Stranded Wire Waterproof Structure for Uniform Void Filling
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Solution Overview
Problem
Existing wire waterproof structures face challenges in ensuring uniform filling of water-stopping materials with fillers in assemblies of multiple strands, leading to insufficient waterproofness and potential cracking under thermal stress.
Innovation Solution
A wire waterproof structure that uses a water-stopping material with a filler dispersed in a resin, where the filler has an average particle size of 1 μm or more and 15% or less of the strand diameter, and a content of 1 mass % or more to 20 mass % relative to the resin, allowing for efficient distribution and curing within minute voids between strands, using either soft or hard fillers to enhance toughness or mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If filler is added to water-stopping material to improve toughness and mechanical strength, then the material properties are improved, but uniform distribution in minute voids between strands becomes difficult to achieve
Solution Approach 1:
The patent specifies precise parameter ranges for filler particle size (1 μm or more and 15% or less of strand outer diameter) and filler content (1 mass% or more and 20 mass% or less relative to resin material). These parameter optimizations enable the filler to distribute uniformly in minute voids while maintaining improved mechanical strength and toughness.
2Reliability
If filler content is increased to enhance waterproofness and material properties, then the effectiveness of water-stopping material is improved, but the material becomes harder to fill uniformly in minute spaces between strands
Solution Approach 1:
The patent optimizes filler content to 1 mass% or more and 20 mass% or less relative to resin material. This parameter range ensures sufficient waterproofness enhancement while maintaining adequate flowability for uniform filling of minute voids between strands during the waterproofing process.
3Strength
If large particle size filler is used to improve mechanical strength, then toughness is enhanced, but the filler cannot sufficiently fill minute voids between strands
Solution Approach 1:
The patent specifies that filler particle size should be 1 μm or more and 15% or less of the outer diameter of strands. This optimized particle size range allows filler particles to penetrate and fill minute voids between strands effectively while still providing the toughness enhancement from filler addition.
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 ensures high uniformity and effectiveness of the water-stopping material in filling minute voids, improving waterproofness and thermal shock resistance, while reducing the likelihood of cracking and maintaining insulation integrity under cooling-heating environments.
Implementation Method 1
the water-stopping material contains a resin material, and a filler dispersed in the resin material
Data Source
AI summary
A wire waterproof structure including a water-stopping material, wherein: the water-stopping material is configured to seal at least a partial region of a conductor comprising an assembly of a plurality of strands, the water-stopping material contains a resin material, and a filler dispersed in the resin material, and the filler has an average particle size of 1 μm or more and 15% or less of an outer diameter of the strands, and a content in the water-stopping material of 1 mass % or more and 20 mass % or less, relative to the resin material.