Waterproofing Structure for Electrical Wire Core Exposed Portion
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Solution Overview
Problem
Existing waterproofing solutions for core wire exposed portions of electrical wires fail to prevent cracking in sealants due to extreme temperature fluctuations, leading to potential water ingress and compromised waterproofing.
Innovation Solution
A waterproofing structure that includes an internal cap housing the core wire exposed portion with a cured water-blocking agent and an exterior member forming a separated space around the internal waterproofing portion, with a gap of at least 1 mm and made of materials like elastomers or thermosetting resins, to mitigate temperature changes and prevent cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealant is used to waterproof the core wire exposed portion, then waterproofing is achieved, but cracking occurs in the cured sealant under extreme temperature conditions
Solution Approach 1:
The waterproofing structure is divided into two separate components: an internal cap containing the cured sealant that directly contacts the core wire, and an external cap that provides thermal insulation. This segmentation allows the sealant to perform its waterproofing function while being protected from extreme temperature fluctuations by the external cap, preventing cracking while maintaining waterproofing integrity.
Solution Approach 2:
The external cap acts as an intermediary between the extreme external environment and the sealant inside the internal cap. By positioning the external cap around the internal cap with its open end facing the extreme environment, it mediates the thermal stress, preventing direct transmission of temperature extremes to the sealant and thus preventing cracking while preserving the sealant's waterproofing capability.
2Temperature
If the exterior member is made thicker to better insulate against temperature changes, then temperature stability improves, but device complexity and material usage increase
Solution Approach 1:
The insulation function is segmented into a separate external cap component rather than integrating it into the internal cap. This allows the external cap to be optimized for thermal insulation with appropriate thickness while keeping the internal cap simple and focused on its waterproofing function, achieving temperature stability without excessive overall complexity.
Solution Approach 2:
The external cap is designed with specific local features: its closed end faces the extreme environment while its open end faces away, creating a localized thermal barrier where it is most needed. The gap between the internal and external caps is maintained at specific locations to allow for thermal expansion and contraction, providing temperature stability without requiring uniform thickening throughout the entire 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
The solution effectively prevents cracking and maintains waterproofing integrity across a wide temperature range, ensuring reliable protection against water ingress and maintaining water-blocking properties.
Implementation Method 1
an exterior member that forms a space that is separated from an external space, around the internal waterproofing portion... changes in temperature are less likely to be transferred to the internal waterproofing portion
Implementation Method 2
a water-blocking agent that has been filled into the internal cap and has been cured... waterproof the core wire exposed portion
Data Source
AI summary
A waterproofing structure 20 for a core wire exposed portion of an electrical wire includes: an electrical wire 10 that includes a core wire exposed portions 12a; an internal waterproofing portion 21 that encloses the core wire exposed portion 12a to waterproof the core wire exposed portion 12a; and an exterior member 30 that forms a space S that is separated from an external space, around the internal waterproofing portion 21.