Waterproof Cable With Nested Resin Layers And Positioning Features
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Solution Overview
Problem
Existing waterproof cable manufacturing methods face challenges in ease of manufacturing and ensuring sufficient waterproofness, particularly due to labor-intensive parts management and potential water infiltration through mold pin holes.
Innovation Solution
A waterproof cable design featuring three resin layers, with positioning convex portions and concave portions to secure accurate positioning and prevent water infiltration, using insert-molding techniques to form a robust and watertight seal between cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a core with positioning side wall pieces is used for waterproof treatment, then waterproofness is secured, but parts management becomes labor-intensive and manufacturing becomes difficult
Solution Approach 1:
The waterproof structure is divided into multiple independent resin layers (first resin layer, second resin layer, third resin layer) that can be manufactured separately and then assembled. Each layer serves a specific waterproofing function, eliminating the need for complex integrated cores while maintaining effective waterproof protection.
Solution Approach 2:
The patent employs a nested structure where the first resin layer contains the connecting part, the second resin layer coats the first resin layer, and the third resin layer coats the second resin layer. This nested arrangement achieves comprehensive waterproof coverage without requiring complex positioning mechanisms, simplifying manufacturing while ensuring reliability.
2Manufacturing precision
If a mold pin is used for positioning in the second molding process, then positioning accuracy is improved, but water can infiltrate through the hole formed for the mold pin
Solution Approach 1:
Positioning convex portions are formed in advance on the first resin layer during the first molding process. These pre-formed positioning features guide the alignment of subsequent resin layers without requiring mold pins that would create infiltration holes, thus maintaining both positioning accuracy and waterproof integrity.
Solution Approach 2:
The patent eliminates the mold pin positioning method that creates holes vulnerable to water infiltration. Instead, positioning is achieved through convex portions that are integral to the resin layers themselves, removing the source of potential water entry while preserving positioning functionality.
3Reliability
If multiple resin layers are used to coat the connecting part, then waterproofness is enhanced, but manufacturing complexity increases
Solution Approach 1:
The waterproofing function is segmented into three distinct resin layers, each with specific positioning features (convex and concave portions) that enable straightforward assembly. This segmentation provides comprehensive waterproof coverage while maintaining manufacturing simplicity through modular construction.
Solution Approach 2:
The patent combines multiple resin layers with integrated positioning features (convex and concave portions) into a unified waterproofing system. The positioning features are built into each layer, merging the positioning and waterproofing functions, which simplifies the overall manufacturing process despite the multi-layer structure.
Data Source
AI summary
To provide a waterproof cable that is easily manufactured and improves waterproofness.The waterproof cable includes: a first cable; a second cable, an end of which is connected with an end of the first cable; a first resin member that coats a connecting part and is formed by insert-molding; a second resin member that coats the first resin member and is formed by insert-molding; and a third resin member that coats the second resin member and is formed by insert-molding.