Wire Bundle Sealing Assembly Using Conductive Heat-Spreading Layers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wire sealing methods face issues such as overheating due to electromagnetic coupling, increased production time and cost from orienting magnetic flakes, and bulkiness from surrounding each wire with a comb, which can damage wire insulation and complicate the sealing process.
Innovation Solution
A sealing assembly comprising a first and second sheet with a thermally conductive material, where the bundle of wires is overlaid and wrapped in a perpendicular direction to facilitate thermal energy distribution, softening the sealant material to fill voids between the wires, and a cover maintains the sealant in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic flakes are used in the sealant and subjected to a strong magnetic field for heating, then the sealant softens and flows to seal the wire bundle, but electromagnetic coupling between the wires and magnetic field may cause overheating and damage wire insulation
Solution Approach 1:
The patent replaces the magnetic field heating method with a conventional thermal heating method. Instead of using magnetic flakes and applying a strong magnetic field, the invention uses external heat sources (heating elements, hot air, or heated molds) to uniformly heat the sealant material. This substitution eliminates the electromagnetic coupling problem that causes overheating and insulation damage while achieving the same sealing effect through controlled thermal softening of the sealant.
Solution Approach 2:
The patent introduces a thermally conductive material as an intermediary between the heat source and the sealant. This intermediary ensures uniform heat distribution throughout the sealant material, preventing localized overheating and ensuring controlled, even softening. The thermally conductive material acts as a heat transfer medium that mediates the heating process to avoid thermal damage to the wires.
2Power
If magnetic flakes of specific composition and configuration are oriented in a particular way when inserted into the sealant, then the magnetic heating effect is optimized, but production time and cost increase
Solution Approach 1:
The patent eliminates the need for magnetic flakes and magnetic field application by substituting with conventional thermal heating methods. This removes the entire magnetic heating system, including the requirement for orienting magnetic flakes, thereby significantly reducing production time and complexity while achieving effective sealing through controlled thermal softening of the sealant material.
Solution Approach 2:
The patent changes the heating parameter from magnetic field energy to thermal energy. By using conventional heat sources and controlling temperature parameters, the invention achieves sealant softening without requiring the complex orientation and positioning of magnetic flakes, thus simplifying the manufacturing process and reducing production time.
3Reliability
If each wire or group of wires is surrounded by a comb formed from sealant material, then sealing coverage is improved, but the bulk of the sealing member increases
Solution Approach 1:
The patent merges multiple individual comb structures into a single integrated sealing member. Instead of surrounding each wire or group of wires with separate comb structures, the invention uses one continuous sealing member that encompasses the entire wire bundle. This consolidation maintains comprehensive sealing coverage while significantly reducing the overall bulk and material usage compared to multiple discrete combs.
Solution Approach 2:
The patent creates a universal sealing member that performs the sealing function for the entire wire bundle simultaneously. This single sealing member is designed to accommodate multiple wires of varying sizes and configurations, providing comprehensive sealing coverage without requiring multiple specialized components, thus reducing overall volume and simplifying the assembly.
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 method effectively seals wire bundles by uniformly melting and filling voids with the sealant, preventing moisture and noise ingress while avoiding overheating and reducing production complexity and costs.
Implementation Method 1
the second sheet includes a thermally conductive material. When the bundle of wires is overlaid on the assembly in a first direction, and the assembly is wrapped in a second direction that is generally perpendicular to the first direction to thereby surround the wires, the second sheet facilitates thermal energy distribution of applied heat throughout the assembly
Implementation Method 2
facilitates thermal energy distribution of applied heat throughout the assembly to thereby soften the sealant material and thereby lower viscosity of the sealant material to a point at which the sealant material flows and fills voids between the bundle of wires
Data Source
AI summary
A sealing assembly for sealing a bundle of wires includes a first sheet formed of a sealant material, a second sheet disposed above the first sheet, and a third sheet disposed above the second sheet formed of the sealant material. The second sheet includes a thermally conductive material. When the bundle of wires is overlaid on the assembly in a first direction, and the assembly is wrapped in a second direction that is generally perpendicular to the first to thereby surround the wires, the second sheet facilitates enhanced thermal energy distribution of applied heat throughout the assembly to thereby more uniformly melt the sealant material and thereby fill voids between the wires.