Cable Terminal Seal Crimping for Diameter-Adaptive Sealing
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Solution Overview
Problem
Conventional electric cable terminal assemblies are costly, complex to manufacture, and fail to adapt to various cable diameters, leading to poor sealing and tensile force issues due to deformation of elastic seals during crimping.
Innovation Solution
A cable terminal assembly with a seal featuring a sealing portion and a shrink-fitting portion, where the shrink-fitting wings are crimped onto the shrink-fitting portion without overlapping, ensuring a secure fit on both the sheathed and stripped cable portions, reducing the number of parts and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rubber seals are used with intermediate parts and forced deformation fixing, then sealing function is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the sealing portion and shrink-fitting portion into a single integrated seal component. The sealing portion ensures moisture and dust protection while the shrink-fitting portion with longitudinal slots allows radial compression for direct mounting on the cable core, eliminating the need for separate intermediate parts and reducing assembly complexity.
Solution Approach 2:
The seal serves multiple functions: the sealing portion provides protective sealing, while the shrink-fitting portion with radial compressibility enables direct mechanical attachment to the cable core. This multi-functionality eliminates the need for separate fixing mechanisms and intermediate components.
2Strength
If elastic seals are crimped to fix the terminal, then fixing is achieved, but severe deformations occur affecting sealing properties and tensile force
Solution Approach 1:
The seal is segmented into two distinct portions: the sealing portion with sealing lips that maintains sealing properties, and the shrink-fitting portion with longitudinal slots that provides radial compressibility. This segmentation allows crimping to be applied only to the shrink-fitting portion without deforming the sealing portion.
Solution Approach 2:
The seal has different local properties: the sealing portion is designed for sealing with intact continuous structure, while the shrink-fitting portion has longitudinal slots that enable radial compression. This local differentiation allows crimping to be applied locally without affecting the sealing function.
3Reliability
If the assembly uses additional reinforcing elements, then crimping protection is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The reinforcing function is merged into the seal itself through the shrink-fitting portion with longitudinal slots. The slots provide radial compressibility and structural integrity during crimping without requiring separate reinforcing elements, reducing the total number of parts.
Solution Approach 2:
The seal's shrink-fitting portion with longitudinal slots inherently provides the reinforcing function needed during crimping. The structure self-reinforces during the crimping process through its radial compressibility and elastic recovery, eliminating the need for additional reinforcing elements.
4Reliability
If the seal is made of elastic material for sealing, then sealing flexibility is achieved, but tensile force requirements are not met after crimping
Solution Approach 1:
The seal is divided into sealing portion and shrink-fitting portion. The shrink-fitting portion's longitudinal slots provide radial compressibility for strong mechanical attachment during crimping, while the sealing portion maintains elastic flexibility for sealing, resolving the conflict between tensile strength and sealing flexibility.
Solution Approach 2:
Different local qualities are provided: the shrink-fitting portion has slots for radial compression and high tensile strength during crimping, while the sealing portion remains continuous and elastic for sealing flexibility. This local differentiation resolves the contradiction between strength and flexibility.
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 solution allows for adaptable assembly across different cable diameters, ensuring effective sealing and tensile strength without damaging the cable or seal, reducing manufacturing costs and improving service life.
Implementation Method 1
the shrink-fitting wings are arranged to crimp (or allow crimping of) the seal at the shrink-fitting portion, so as to clamp it vigorously (i.e. firmly)
Implementation Method 2
since the known seals are made of elastic material, the crimping can cause severe deformations of the seal
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
Method for crimping a cable terminal (10) on an electric cable (1), with the following steps: • Providing an electric cable (1) having an outer insulation sheath (3) and at least one conductive strand (2), with a sheathed portion (1g), • Providing a terminal (10) having shrink-fitting wings (15) and providing a seal (11) having a sealing portion (14) and a shrink-fitting portion (12), • Stripping the electric cable (1) so as to form a stripped portion (1d), • Positioning the shrink-fitting portion (12) of the seal (11) so as to directly cover the stripped portion (1d) of the cable (1), without the shrink-fitting portion (12) covering the sheathed portion (1g) of the cable (1), • Fully crimping the shrink-fitting wings (15) on the shrink-fitting portion (12) of the seal (11) without the shrink-fitting wings (15) covering the sheathed portion (1g) of the cable (1).