Tearable Cable End Seal with Stepped Tear Stop Members
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors fail to provide effective sealing for a wide range of wire and cable sizes, leading to potential leaks and inadequate accommodation of varying cable dimensions.
Innovation Solution
An electrical connector design featuring a resilient, tearable cable end seal with a first tear stop member and a second tear stop member having progressively decreasing diameters, made from materials like silicone, thermoplastic elastomer, or rubber, which effectively seals and accommodates different cable sizes by tearing to form a tight seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single-size seal is used in existing electrical connectors, then the manufacturing and installation is simple, but the connector cannot effectively seal cables of varying sizes
Solution Approach 1:
The seal is divided into multiple telescoping segments that can independently expand and contract. Each segment contains tear stop members that can be torn to accommodate different cable sizes. This segmentation allows the seal to adapt to various cable diameters while maintaining a relatively simple overall structure.
Solution Approach 2:
The seal incorporates dynamic tear stop members that can be torn or broken during installation to adjust the seal's internal diameter. This dynamic characteristic allows the seal to transition from a compact stored state to an expanded sealed state, accommodating different cable sizes without requiring multiple seal components.
2Adaptability or versatility
If a rigid seal structure is used, then the seal provides strong sealing force, but it cannot stretch to accommodate different cable diameters
Solution Approach 1:
The seal is constructed from resilient, tearable material that forms a flexible shell structure. This flexible material can stretch and deform to accommodate different cable diameters while maintaining sealing integrity. The flexibility is achieved through the material's ability to elastically deform and the presence of tear stop members that can be torn to adjust the fit.
Solution Approach 2:
The seal uses composite construction combining resilient tearable material with reinforced ribs and tear stop members. This composite structure provides both the flexibility needed to stretch over different cable sizes and the structural integrity required to maintain reliable sealing. The combination of materials allows the seal to be both compliant and strong.
3Adaptability or versatility
If the seal material is made highly resilient and tearable, then it can accommodate various cable sizes, but the material strength may be compromised
Solution Approach 1:
The seal incorporates localized reinforcement through ribs and tear stop members positioned at specific locations. These localized strong points provide structural support and control the tearing process, while the rest of the seal material remains highly resilient and tearable. This local quality approach allows the seal to have both strength where needed and flexibility where required.
Solution Approach 2:
The tear stop members are pre-positioned in the seal structure to control where and how the material will tear. This preliminary arrangement ensures that when the seal is installed, the material tears in a controlled manner to accommodate the cable size without compromising overall structural integrity. The pre-planned tear paths maintain strength while enabling adaptability.
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 connector provides reliable sealing and accommodates a wide range of wire and cable sizes, ensuring a secure and environmental seal across various dimensions without undue stress, using a tearable material that can stretch to accommodate different cable diameters.
Implementation Method 1
a resilient, tearable cable end seal (45)... made from materials like silicone, thermoplastic elastomer, or rubber... that can stretch to accommodate different cable diameters
Implementation Method 2
a first tear stop member (49) and a second tear stop member (55)... which effectively seals and accommodates different cable sizes by tearing to form a tight seal
Data Source
AI summary
An electrical connector for a plurality of electrical cables includes an electrically conductive body having a plurality of spaced apart cable-receiving passageways for receiving respective electrical cable ends therein, and having at least one respective fastener-receiving passageway intersecting each of the cable-receiving passageways. An insulating cover is on the electrically conductive body and has a respective cable inlet aligned with each of the cable-receiving passageways. A respective cable end seal is associated with each of the cable inlets and includes a first tear stop member having a planar portion defining a central opening, and at least one coaxial and coplanar rib extending from the planar portion and spaced from the central opening. A second tear stop member is coupled to the first annular tear stop member at the central opening and includes a series of stepped tear stop portions having progressively decreasing diameters.