Wire Terminal Sealing Member for Liquid Penetration Prevention

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Solution Overview

Problem

Existing wire with terminal solutions are inefficient in preventing liquid penetration to the connector terminal, requiring complex manufacturing processes and multiple steps, especially when exposed to liquids like oil or water, which can penetrate through capillary gaps between conductors.

Innovation Solution

A wire with a single-core conductor and an insulation coating, combined with a sealing member that closes the clearance between the conductor and the insertion hole, preventing liquid penetration by filling gaps and using caulking or welding for electrical connections, thereby simplifying the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a wire with multiple bundled conductors is used, then electrical connectivity is improved, but liquid penetration risk increases due to gaps between conductors

Engineering Contradiction:

Improveelectrical connectivityVSAvoidliquid penetration risk

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a sealing member as an intermediary substance between the bundled conductors and the insulation coating. This sealing member fills the gaps between conductors, preventing liquid penetration while maintaining the electrical connectivity benefits of multiple bundled conductors.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent uses a flexible sealing member that can adapt to the irregular spaces between bundled conductors. This sealing member acts as a flexible barrier that prevents liquid penetration without restricting the electrical functionality of the wire assembly.

Inventive Principle:

Principle #30Flexible shells and thin films

2Object-affected harmful factors

If insulation coating is stripped at intermediate position to form core exposed portion, then liquid sealing capability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveliquid sealing capabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent extracts the sealing function from the insulation coating itself and implements it through a separate sealing member. This eliminates the need to strip the insulation coating, as the sealing member provides the necessary liquid barrier without requiring exposure of the core conductors.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of removing the insulation coating to create a sealing structure, the patent inverts the approach by adding a sealing member over the insulated conductors. This reverse approach achieves liquid sealing without the complexity of stripping and re-insulating operations.

Inventive Principle:

Principle #13The other way round (Inversion)

3Object-affected harmful factors

If waterproofing agent is filled and cured before covering with waterproof sheet, then liquid penetration prevention is improved, but manufacturing time increases

Engineering Contradiction:

Improveliquid penetration preventionVSAvoidmanufacturing time

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The patent replaces the multi-step process involving waterproofing agents that require curing time with a pre-formed sealing member. This sealing member provides immediate liquid protection without requiring chemical curing processes, significantly reducing manufacturing time.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The sealing member is pre-formed and ready for installation, eliminating the need for on-site application and curing of waterproofing agents. This preliminary preparation of the sealing component streamlines the manufacturing process and reduces overall production time.

Inventive Principle:

Principle #10Preliminary action

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

Effectively prevents liquid penetration to the connector terminal, improving manufacturing efficiency and productivity by reducing the number of steps in mounting the sealing member and ensuring the connector terminal remains dry, even when exposed to liquids.

Implementation Method 1

A liquid that contacts an end part of the wire connected to the electronic device is known to penetrate through gaps between the conductors of the wire by a capillary phenomenon

Methodology Applied

Scientific EffectCapillary phenomenon: Capillary Action

Data Source

PatentUS10355395B2Wire with terminal

Publication Date: 2019.07.16 AUTONETWORKS TECH LTD

AI summary

A wire with terminal (1) includes a single-core wire (3), a connector terminal (2) and a seal (5). The wire (3) includes one conductor (31) and an insulation coating layer (32) covering the conductor (31). The wire (3) is formed with a conductor portion (310) that is part of the conductor (31) projecting from an end of the insulation coating layer (32). The connector terminal (2) is connected to the conductor portion (310) and arranged in an insertion hole (71) in a case (7). The seal (5) is mounted on an outer periphery of the conductor portion (310) and in the insertion hole (71) and closes a clearance (S1) between the inner periphery of the seal (5) and the outer periphery of the conductor portion (310) and a clearance (S2) between the outer periphery of the sealing member (5) and the inner periphery of the insertion hole (71).