Wire Bundle Sealing Assembly With Conductive Heat Distribution
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Solution Overview
Problem
Existing wire sealing methods face issues such as overheating due to electromagnetic coupling, increased production time and cost from specific magnetic material orientation, and bulkier sealing members, which can damage wire insulation and complicate the sealing process.
Innovation Solution
An integrated sealing assembly comprising a first sheet of sealant material, a second sheet with thermally conductive material, and a third sheet with teeth for controlled wire placement, where the assembly is wrapped perpendicular to the wire direction to distribute heat and soften the sealant, filling voids between wires, and a heat-shrinkable cover is used to maintain the sealant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic flakes are used in the sealant composite material 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 removes the magnetic flakes from the sealant composite material entirely, extracting the harmful electromagnetic coupling effect while retaining the sealing function through alternative heating methods that do not induce electromagnetic currents in the wires
Solution Approach 2:
The patent introduces an intermediary heating mechanism that heats the sealant without using magnetic field interaction with magnetic flakes, thereby avoiding the harmful electromagnetic coupling between the magnetic field and conductive wires while still achieving the desired softening and flow of sealant material
2Reliability
If magnetic flakes of specific composition and configuration are oriented in a particular way when inserted into the sealant, then the sealing performance is optimized, but production time and cost increase
Solution Approach 1:
The patent eliminates magnetic flakes from the sealant formulation, thereby removing the requirement for specific orientation of magnetic particles during manufacturing, which significantly reduces production complexity, time, and cost while maintaining effective sealing through the alternative heating mechanism
3Reliability
If each wire or group of wires is surrounded by a comb or ring or sleeve formed from sealant composite material, then the sealing coverage is improved, but the bulk of the sealing member increases
Solution Approach 1:
The patent merges multiple separate sealing elements (combs, rings, or sleeves) into a single integrated sealant material application that surrounds the entire wire bundle, reducing the overall bulk and complexity of the sealing member while maintaining comprehensive sealing coverage through the unified structure
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 the sealant to fill voids without overheating, reducing production costs and complexity, while maintaining a watertight and sound-dampening seal.
Implementation Method 1
the second sheet facilitates thermal energy distribution of applied heat throughout the assembly to thereby soften the sealant material
Implementation Method 2
the sealant material of the integrated sealing assembly fills voids between the one or more wires
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3A
AI summary
A sealing assembly (100) for sealing a bundle of wires (305) includes a first (105a) formed of a sealant material, a second sheet (107) disposed above the first sheet, and a third sheet (105b) 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.