Electric Wire Connection Sealing for Stable Temperature Sensor Contact
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Solution Overview
Problem
Existing electric wire units face challenges in stably maintaining a temperature sensor at the electric wire connection portion, leading to increased assembly complexity and difficulty in directly detecting the temperature of the heat generator.
Innovation Solution
The electric wire unit employs a sticky tape with an adhesive to securely fix a temperature sensor to the electric wire connection portion, ensuring direct contact and a stable posture, using a thermoplastic adhesive that melts and solidifies for a liquid-tight seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensor-fixing shrinkable tube is used to fix the temperature sensor, then the temperature sensor can be fixed to the waterproof shrinkable tube, but it becomes difficult to stably maintain the temperature sensor at an appropriate position and the assembly process becomes more complicated
Solution Approach 1:
The patent combines the temperature sensor fixing function with the waterproof sealing function by integrating the temperature sensor into the waterproof shrinkable tube structure. The temperature sensor is embedded within the waterproof shrinkable tube, eliminating the need for a separate sensor-fixing shrinkable tube. This merging of functions simplifies the assembly process while ensuring stable positioning and reliable waterproof sealing.
Solution Approach 2:
The patent extracts the temperature sensor from the traditional external mounting position and relocates it inside the waterproof shrinkable tube. This extraction allows the temperature sensor to be positioned more stably at the electric wire connection portion while being protected by the waterproof shrinkable tube, reducing assembly complexity.
2Reliability
If the temperature sensor is attached onto the waterproof shrinkable tube, then the temperature sensor can be fixed, but a separate member is interposed between the temperature sensor and the terminal making temperature detection less accurate
Solution Approach 1:
The patent uses the waterproof shrinkable tube as an intermediary structure that simultaneously serves as both the fixing mechanism and the temperature transmission medium. The waterproof shrinkable tube is in direct thermal contact with the electric wire connection portion, allowing accurate temperature detection while providing mechanical fixation.
Solution Approach 2:
The patent merges the temperature detection function directly with the waterproof sealing structure. The temperature sensor is positioned to detect temperature through the waterproof shrinkable tube material itself, eliminating the need for separate fixing members that would interfere with thermal contact.
3Adaptability or versatility
If multiple separate components (waterproof shrinkable tube and sensor-fixing shrinkable tube) are used, then each component can perform its specific function, but the number of assembly steps and required man-hours increase
Solution Approach 1:
The patent merges multiple separate components into a single integrated waterproof shrinkable tube structure that performs both waterproof sealing and temperature sensor fixation functions. This eliminates the need for two separate shrinkable tubes and reduces the assembly process to a single heating and shrinking step, significantly improving productivity.
Solution Approach 2:
The waterproof shrinkable tube is designed to serve multiple functions simultaneously: providing waterproof sealing for the electric wire connection portion and providing fixation for the temperature sensor. This multi-functionality reduces the total number of components needed while maintaining all required functionalities.
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 allows for easy and stable fixation of the temperature sensor, enabling direct temperature detection of the electric wire connection portion while simplifying the assembly process and reducing material complexity.
Implementation Method 1
a waterproof member that liquid-tightly covers peripheries of the electric wire connection portion and the electric wire, and the waterproof member is constituted by a sticky tape having an adhesive
Implementation Method 2
using a thermoplastic adhesive that melts and solidifies for a liquid-tight seal
Data Source
AI summary
An electric wire unit includes an electric wire, a terminal, a temperature sensor, and a waterproof member. The electric wire includes a conductor and an insulating sheath. The terminal includes an electric wire connection portion connected to the conductor of the electric wire. The temperature sensor detects the temperature of the electric wire connection portion. The waterproof member liquid-tightly covers the peripheries of the electric wire connection portion and the electric wire. The waterproof member is constituted by a sticky tape having an adhesive. The sticky tape having the adhesive is wound, in a state where the temperature sensor is in contact with the electric wire connection portion, around outer peripheral surfaces of the electric wire connection portion and the temperature sensor and an outer peripheral surface of the electric wire.