Dual-Layer Waterproof Lead Wire Assembly for High-Pressure Sealing
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Solution Overview
Problem
Conventional electrical assembly structures fail to prevent liquid infiltration and corrosion under high water pressure due to lead wire deformation, leading to malfunction and potential breakage.
Innovation Solution
A dual-layer waterproof system comprising a first layer made of polyurethane or thermosetting material and a second layer made of polymer, rubber, or silicone, where the second layer is softer and fills deformation gaps to prevent liquid ingress, while allowing easy detachment and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single waterproof layer is used to cover the lead wire, then the structure is simple, but under high water pressure the lead wire deforms and creates gaps allowing liquid infiltration
Solution Approach 1:
The waterproof layer is divided into two distinct layers: a first waterproof layer covering the electric unit and inner section, and a second waterproof layer covering the intermediate section. This segmentation allows each layer to perform its specific function - the first layer provides structural protection while the second layer accommodates lead wire deformation, thereby maintaining waterproof performance without excessive complexity
Solution Approach 2:
Different regions of the waterproofing system are assigned different material properties. The first waterproof layer uses a harder material for structural integrity, while the second waterproof layer uses a softer material that can deform with the lead wire. This local differentiation of material quality ensures both structural support and adaptability to pressure-induced deformations
2Stability of the object's composition
If a hard waterproof material is used to maintain structural integrity, then the waterproof layer remains stable, but it cannot fill gaps created by lead wire deformation under pressure
Solution Approach 1:
The first waterproof layer uses a harder material (polyurethane or thermosetting material) for stability and structural integrity, while the second waterproof layer uses a softer material (polymer, rubber, or silicone) that can deform and fill gaps. This local quality differentiation resolves the contradiction by assigning different material properties to different functional requirements
Solution Approach 2:
The waterproofing system employs a composite structure with two different materials having distinct properties. The combination of hard first layer and soft second layer creates a composite waterproofing system that simultaneously achieves structural stability and gap-sealing capability under pressure
3Reliability
If the lead wire is rigidly fixed to prevent deformation, then waterproofing is maintained, but the lead wire is prone to breakage and disengagement
Solution Approach 1:
The lead wire is divided into three sections with different characteristics: an inner section connected to the electric unit, an intermediate section covered by the second waterproof layer, and an outer section exposed outside. This segmentation allows the intermediate section to be protected and flexible while maintaining connection integrity, reducing breakage risk
Solution Approach 2:
The second waterproof layer is provided beforehand to cover and protect the intermediate section of the lead wire. This protective layer acts as a cushion that absorbs pressure and prevents direct stress on the lead wire, thereby preventing breakage and disengagement while maintaining waterproof performance
4Reliability
If a single integrated waterproof assembly is used, then waterproofing is effective, but maintenance and replacement are difficult
Solution Approach 1:
The electrical assembly structure is segmented into replaceable modules: the electric unit with its first waterproof layer can be independently replaced, and the lead wire with its second waterproof layer can be independently replaced. This modular segmentation maintains effective waterproofing through proper layer coverage while enabling easy maintenance and replacement of damaged components
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 dual-layer system effectively prevents liquid ingress under high pressure, ensuring the electrical assembly's integrity and facilitating easy maintenance by allowing individual replacement of damaged components.
Implementation Method 1
the lead wire is apt to deform under high pressure, resulting in gaps between the lead wire and the waterproof layer
Implementation Method 2
A material of the second waterproof layer is softer than a material of the first waterproof layer
Data Source
AI summary
An electrical assembly structure includes electric circuitry, a first waterproof layer, and a second waterproof layer. The electric circuitry includes an electric unit and a lead wire electrically connected to the electric unit. The lead wire includes an inner section, an outer section, and an intermediate section between the inner section and the outer section. The inner section is connected to the electric unit. The first waterproof layer covers the electric unit and the inner section. The second waterproof layer covers the intermediate section and is connected to the first waterproof layer. The second waterproof layer is located between the outer section and the first waterproof layer. The outer section is exposed outside the second waterproof layer. A material of the second waterproof layer is softer than a material of the first waterproof layer. Motors including the electrical assembly structure are also disclosed.