Novel waterproof connector and manufacturing process thereof

Abstract

The invention discloses a novel waterproof connector and a manufacturing process thereof, and relates to the technical field of electrical connectors, the novel waterproof connector comprises a split shell assembly, an upper shell and a lower shell form a cavity, the interior of the cavity is connected through a plug connector, and the exterior of the cavity is connected through a locking fastener; the inner core assembly is mounted in the cavity and comprises a forming seat and a terminal assembly; a transverse channel and a longitudinal channel which are communicated are arranged in the lower shell, and a boosting assembly and an airtight assembly are arranged in the transverse channel and the longitudinal channel respectively and used for attaching or separating the upper shell and the lower shell; and a sealing assembly is also used for sealing the end connection of the terminal assembly. In addition, the invention also comprises a manufacturing process of the novel waterproof connector. The manufacturing process comprises the steps of raw material preparation, terminal processing, assembling, sealing and the like. Waterproof sealing of the connector is realized, stable connection is ensured, and the manufacturing process can ensure accurate positioning and waterproof effects of the inner core assembly.

Description

Technical Field

[0001] This application relates to the field of electrical connector technology, and in particular to a novel waterproof connector and its manufacturing process. Background Technology

[0002] In the field of connector technology, with the widespread application and continuous development of various electronic devices, connectors, as indispensable components, play a crucial role in the normal operation of these devices due to their performance and quality. Especially in applications with high waterproofing requirements, such as outdoor electronic equipment and underwater work equipment, the demand for waterproof connectors is increasing. The use of waterproof connectors can effectively prevent moisture from penetrating the interior of electronic devices, protecting the circuits and components from damage, thereby improving the reliability and stability of the equipment and extending its service life.

[0003] Previously, several methods were commonly used to address the waterproofing issue of connectors. One common method was to use sealing rings. By installing sealing rings at the connector interface, the elasticity of the rings filled the gaps at the interface, preventing water ingress. This method was simple, easy to implement, and relatively inexpensive, and was widely used in applications where waterproofing requirements were not particularly high. Another method was to use potting compound. Potting compound was injected into the connector, sealing the various components within the compound layer, thus achieving waterproofing. Potting compound provides good waterproofing and offers some protection to the internal components. Additionally, some methods employed waterproof coatings. A waterproof coating was applied to the surface of the connector to block moisture intrusion. This method can improve the waterproofing performance of the connector to some extent, but the durability and reliability of the coating may be affected by various factors.

[0004] The existing drawbacks are as follows: with the use of sealing rings, the rings are prone to wear and aging over time and with frequent insertion and removal operations, resulting in a decrease in sealing performance and inability to effectively prevent moisture intrusion; although potting compound has a better waterproof effect, it is difficult to repair and replace components once the connector malfunctions, and the curing process of potting compound may have a certain impact on the performance of the connector; the waterproof coating method may lose its waterproof function due to the coating peeling off or being damaged. Summary of the Invention

[0005] To address the issues of poor sealing and waterproofing caused by aging and wear of existing sealing rings, decreased sealing performance, and the inability of integrated potting type to achieve internal replacement and maintenance, this application provides a novel waterproof connector and its manufacturing process.

[0006] This application provides a novel waterproof connector and its manufacturing process, which adopts the following technical solution: A novel waterproof connector includes: a housing assembly with a split structure, having an upper housing and a lower housing, the upper housing and the lower housing forming a cavity, the interior of the upper housing and the lower housing being connected by a plug-in member, the lower housing having a through hole communicating with the cavity, and the exterior of the upper housing and the lower housing being connected by a locking member; An inner core assembly is installed in a cavity. The inner core assembly has an installation channel that communicates with a through hole. The inner core assembly includes a molding seat and a terminal assembly installed in the installation channel. The lower housing has a transverse channel and a longitudinal channel that are connected. A propulsion component is arranged in the transverse channel, and an airtight component for attaching or detaching the upper and lower housings is arranged in the longitudinal channel. The end of the propulsion component away from the airtight component contacts the forming seat. The forming seat is subjected to force and abuts against the propulsion component. The propulsion component squeezes the airtight component to make the connection between the lower and upper housings fit tightly. When the pressure applied by the forming seat decreases or disappears, the airtight component drives the connection between the lower and upper housings to separate. Sealing assemblies are respectively arranged at the ends of the terminal assemblies in the upper and lower housings for sealing the end connections of the terminal assemblies.

[0007] By adopting the above technical solution, the split structure of the outer shell assembly facilitates assembly and disassembly. The upper and lower shells are connected internally by plug-in connectors and externally by locking fasteners, ensuring a stable connection. The inner core assembly is installed in the cavity, and the installation channel is connected to the through hole, facilitating the passage of the terminal assembly. The push assembly and the airtight assembly work together to allow the upper and lower shells to fit together or separate according to the stress on the molding seat, enhancing waterproof performance. The sealing assembly is arranged at the end of the terminal assembly to seal the connection at the end of the terminal assembly, further improving the waterproof effect.

[0008] Optionally, the connector includes a fork plate formed at one end of the upper housing near the lower housing and an extension plate formed at one end of the lower housing near the upper housing. The fork plate is elastic, the extension plate is rigid, the fork plate has a Y-shaped structure, and the extension plate and the fork plate are engaged by plugging.

[0009] By adopting the above technical solution, the upper and lower housings are connected by a flexible Y-shaped fork plate and a rigid extension plate. The flexible fork plate ensures the tightness of the connection and improves the overall stability and connection strength of the waterproof connector.

[0010] Optionally, the terminal assembly includes a main terminal and a secondary terminal. The secondary terminals are arranged around the main terminals, and the angle between adjacent secondary terminals is an acute or obtuse angle. Both the main terminal and the secondary terminal have a rod portion, a torque portion, and a guide portion. The rod portion, torque portion, and guide portion are sequentially injection molded. The guide portions of the main terminal and the secondary terminal are arranged in parallel. The torsion angle of the torque portion of the main terminal is greater than that of the torque portion of the secondary terminal. The cross-sectional surface of the rod portion of the main terminal is greater than that of the rod portion of the secondary terminal. The side of the main terminal forms a chamfered surface, which fits against the inner wall of the mounting channel. The angled surface formed by the rod portion of the main terminal / secondary terminal abuts against the upper housing.

[0011] By adopting the above technical solution, the main and auxiliary terminals are injection molded sequentially to ensure structural stability. The auxiliary terminals are arranged around the main terminals with acute or obtuse angles to make reasonable use of space. The parallel arrangement of the main and auxiliary terminal guides facilitates installation. The torsion angle of the main terminal torque section is greater than that of the auxiliary terminal to adapt to different needs. The cross-sectional area of ​​the main terminal rod is larger than that of the auxiliary terminal to distinguish functions. The chamfered surface of the main terminal side fits against the inner wall of the installation channel to achieve precise positioning. The bends of the main and auxiliary terminal rods abut against the upper housing to ensure that the terminal assembly is installed firmly.

[0012] Optionally, the molding base consists of an upper base with a polygonal structure and a lower base integrally molded on the upper base, wherein the side of the upper base forms a guide surface and the inner wall shape and specifications of the cavity correspond to each other.

[0013] By adopting the above technical solution, the molding base consists of a polygonal upper base and an integrated lower base. The side guide surface of the upper base corresponds to the shape and specifications of the inner wall of the cavity, which facilitates the installation and positioning of the molding base in the cavity, ensures the installation accuracy and stability of the inner core components, and improves the overall performance and waterproof effect of the connector.

[0014] Optionally, the booster assembly includes a first wedge integrally formed at the bottom of the molding base, a second wedge that cooperates with the first wedge and is installed in the transverse channel, and a telescopic rod installed on the side of the second wedge away from the first wedge. The second wedge, the upper housing, and the airtight assembly together form a sealed space. The second wedge moves along the transverse channel to cause the airtight assembly and the second wedge to press against each other or move away from each other.

[0015] By adopting the above technical solution, the first wedge at the bottom of the molding base and the second wedge installed in the transverse channel can move the second wedge along the transverse channel when the molding base is subjected to force. The sealed space constructed by the second wedge, the upper housing and the airtight component can ensure the normal operation of the airtight component. Moreover, the movement of the second wedge can squeeze or move away from the airtight component, so that the upper housing and the lower housing can be close or separate, thereby realizing the opening and closing and sealing and waterproof functions of the connector.

[0016] Optionally, the airtight assembly includes a plastic volume arranged in a longitudinal channel, an elastic one-way valve installed at the input end of the plastic volume, and an output end of the plastic volume connected to a cavity formed in the fork plate. The input end of the plastic volume located in the lower housing is also provided with a return pipe, and the return pipe extends out of the side of the lower housing and is also provided with a pressure relief valve for controlling its opening and closing.

[0017] By adopting the above technical solution, when the molding seat is subjected to force and abuts against the booster component, and the booster component squeezes the airtight component, the elastic one-way valve is opened, and the medium in the longitudinal channel is pressed into the bladder in the fork plate. The fork plates on both sides abut against each other towards the extension plate, so that the upper and lower shells are tightly attached, ensuring the sealing performance of the waterproof connector. When the pressure applied by the molding seat decreases or disappears, the pressure relief valve drives the pressure difference in the plastic volume to balance, the elastic one-way valve closes, and the abutting action of the fork plates towards the extension plate gradually decreases, causing the upper and lower shells to separate.

[0018] Optionally, the locking element includes a locking piece mounted on the outer wall of the lower housing and a retaining ring mounted on the outer wall of the upper housing, wherein the retaining ring and the locking piece are fastened together.

[0019] By adopting the above technical solution, the fastening fit between the locking plate and the retaining ring achieves a tight and stable fit on the connector axis.

[0020] Optionally, the sealing assembly includes a first sealing ring and a second sealing ring, wherein the first sealing ring is mounted on a terminal assembly located inside the lower housing, and the second sealing ring is mounted on a terminal assembly located in the upper housing.

[0021] By adopting the above technical solution, the ends of the upper and lower shells are sealed to form a secondary waterproof seal.

[0022] Optionally, the end face of the main terminal / sub-terminal facing the bottom wall of the mounting channel has a recessed groove, and the end face of the mounting channel facing the main terminal / sub-terminal has a protrusion that matches the recessed groove. The cross-section of the protrusion is any one of spherical, arc-shaped, and conical.

[0023] By adopting the above technical solutions, the installation of the main or auxiliary terminals with the mounting channel is more stable and precise, thereby improving the overall stability and reliability of the connector.

[0024] Optionally, a telescopic component for resetting the second wedge is also provided in the transverse channel. One end of the telescopic component is connected to the second wedge, and the other end of the telescopic component is connected to the inner wall of the transverse channel. The end of the second wedge away from the first wedge is elastic. The second wedge moves along the transverse channel toward the plastic volume, and the second wedge squeezes the plastic volume to open the elastic one-way valve. The medium in the longitudinal channel is pressed into the cavity in the fork plate, and the fork plates on both sides abut against each other toward the extension plate. The second wedge moves away from the plastic volume, and the pressure relief valve drives the pressure difference in the plastic volume to balance, the elastic one-way valve closes, and the abutting action of the fork plate toward the extension plate gradually decreases.

[0025] By adopting the above technical solution, the telescopic component can reset the second wedge. The elasticity of the second wedge is conducive to compressing the plastic volume. The compression of the plastic volume by the second wedge causes the elastic one-way valve to open, and the medium is pressed into the inner cavity of the fork plate, so that the fork plate and the extension plate abut against each other, realizing the precise positioning of the inner core component and the cavity and the initial waterproof seal of the upper and lower shells. When the second wedge moves away from the plastic volume, the pressure relief valve balances the pressure difference in the plastic volume, causing the elastic one-way valve to close, reducing the abutment of the fork plate against the extension plate, and facilitating the separation of the upper and lower shells.

[0026] A novel waterproof connector manufacturing process, employing the aforementioned novel waterproof connector, includes the following steps: Step 1: Prepare raw materials, bend and shape the main terminals and auxiliary terminals according to specifications, and injection mold them into molded bases; Step 2: Electroplating treatment of the main and auxiliary terminals, chamfering, roughening and passivation treatment of the guide parts; Step 3: The main terminals and auxiliary terminals are pre-installed on the molding base in sequence through the installation channel. The upper and lower shells are formed by injection molding, cooling and demolding. The inner core components are pre-installed in the upper and lower shells to form cavities. Step 4: The molding seat and the upper shell are aligned with the lower shell and assembled. The molding seat is pressed at the bottom of the cavity. The first wedge block abuts against the second wedge block and moves along the transverse channel to compress the plastic volume. The elastic one-way valve is opened, and the medium flows along the longitudinal channel towards the cavity. The Y-shaped structure insert plate abuts against the extension plate to ensure that the inner core component and the cavity are accurately positioned. The upper shell and the lower shell initially form a waterproof seal. Step 5: The upper housing's retaining ring and the lower housing's locking plate are locked together to achieve a tight and secure fit on the connector's axis.

[0027] Step 6: The first and second sealing rings seal the ends of the upper and lower housings, forming a secondary waterproof seal.

[0028] By adopting the above technical solutions, the bending and forming of main and auxiliary terminals, injection molding of the base, electroplating of the main and auxiliary terminals, and chamfering of the guide parts ensure the performance and accuracy of the terminals. The main and auxiliary terminals are pre-installed into the molding base, and then the upper and lower shells are injection molded and the inner core assembly is pre-installed to prepare for subsequent assembly. The molding base and the upper shell are aligned with the lower shell and assembled. The first wedge block is used to press the second wedge block to compress the plastic volume, so that the Y-shaped insert plate abuts against the extension plate, which determines the precise positioning of the inner core assembly and the cavity and initially forms a waterproof seal. The retaining ring and locking plate lock together to achieve a tight and stable fit on the connector axis. The first sealing ring and the second sealing ring seal the ends of the upper and lower shells, which can form a secondary waterproof seal and enhance the waterproof performance of the waterproof connector.

[0029] In summary, this application includes at least one of the following beneficial technical effects: 1. The outer shell assembly adopts a split structure. The upper and lower shells are internally connected by a connector consisting of a fork plate and an extension plate, and externally connected by a locking mechanism. Sealing components are respectively arranged at the ends of the terminal assemblies within the upper and lower shells to seal the end connections of the terminal assemblies. The molding seat in the inner core assembly is subjected to force, which abuts against the pusher component. The pusher component compresses the airtight component to make the connection between the lower and upper shells tight. As the pressure applied by the molding seat decreases or disappears, the airtight component drives the connection between the lower and upper shells to separate, effectively preventing moisture intrusion. This solves the problems of easy wear and aging of the sealing ring, difficult maintenance of the potting compound, and easy peeling of the waterproof coating in existing technologies, greatly improving the waterproof performance of the connector. 2. The terminal assembly includes main terminals and auxiliary terminals. The auxiliary terminals are arranged around the main terminals, and the angle between adjacent auxiliary terminals is acute or obtuse. Both the main terminals and auxiliary terminals have a rod, a torque section, and a guide section, which are injection molded in sequence. The guide sections of the main terminals and auxiliary terminals are arranged in parallel. The torsion angle of the torque section of the main terminal is greater than that of the torque section of the auxiliary terminal. The cross-sectional surface of the rod of the main terminal is greater than that of the rod of the auxiliary terminal. The side of the main terminal forms a chamfered surface that fits against the inner wall of the mounting channel. The angled surface formed by the rod of the main / auxiliary terminal abuts against the upper housing, which can better realize the electrical connection function and ensure the connection stability of the connector. 3. The upper and lower housings are connected via a specific fork plate and extension plate insertion, and a snap-fit ​​ring and locking plate fastening mechanism. Simultaneously, the airtight assembly and the push-pull assembly work together. When the forming seat is subjected to force, the push-pull assembly compresses the airtight assembly, ensuring the lower and upper housings are tightly fitted together, guaranteeing precise positioning of the inner core assembly and cavity. When the pressure applied by the forming seat decreases or disappears, the airtight assembly separates the lower and upper housings. This design enables precise positioning and a good fit during connector assembly and use, improving the connector's assembly accuracy and reliability. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 This is a schematic diagram illustrating the overall structure of this application.

[0032] Figure 2 This is an exploded view showing the overall structure of this application.

[0033] Figure 3 This is a cross-sectional view of the housing assembly shown in this application.

[0034] Figure 4 This is a schematic diagram of the structure of the molding base shown in this application.

[0035] Figure 5 This is a schematic diagram of the terminal assembly shown in this application.

[0036] Figure 6 This application demonstrates Figure 1 Enlarged view of the locking fastener from direction A.

[0037] Figure 7 This application shows a sectional view of the installation channel.

[0038] Figure 8 This is a partial sectional view of the overall structure shown in this application.

[0039] Figure 9 This application demonstrates Figure 8 A magnified view from direction B.

[0040] Reference numerals: 1. Outer shell assembly; 11. Upper shell; 12. Lower shell; 13. Cavity; 14. Perforation; 15. Locking element; 151. Locking plate; 152. Buckle; 101. Fork plate; 102. Extension plate; Inner core assembly; 21, molding base; 211, upper base; 212, lower base; 22. Terminal assembly; 221. Main terminal; 222. Sub-terminal; 2200. Rod; 2201. Torque section; 2202. Guide section; 201. Protrusion; 202. Recessed groove; 3. Horizontal passageway; 4. Vertical passageway; 5. Boosting assembly; 51. First wedge; 52. Second wedge; 53. Telescopic rod; 6. Airtight components; 61. Plastic volume; 62. Flexible check valve; 63. Chamber; 64. Return line; 65. Pressure relief valve; 7. Sealing assembly; 71. First sealing ring; 72. Second sealing ring. Detailed Implementation

[0041] The following is in conjunction with the appendix Figure 1-9 This application will be described in further detail. Example

[0042] The novel waterproof connector provided in this application embodiment is described in [reference]. Figure 1 and Figure 3 As shown, the assembly includes an outer shell assembly 1, an inner core assembly 2, and an airtight assembly 6. The upper shell 11 and lower shell 12 of the outer shell assembly 1 are connected by a connector and a locking member 15 to form a cavity 13. The inner core assembly 2 is installed in the cavity 13 and its installation channel communicates with the through hole 14 of the lower shell 12. The push-assist assembly 5 and the airtight assembly 6 in the lower shell 12 cooperate to make the upper shell 11 and lower shell 12 fit together or separate in different states. The sealing assembly 7 is used to seal the end connection of the terminal assembly 22, achieving effective waterproofing, convenient maintenance, and stable connection. The split design of the outer shell assembly 1 facilitates assembly and maintenance. The airtight assembly 6 can adjust the connection state of the upper shell 11 and lower shell 12 according to the stress of the inner core assembly 2, enhancing waterproof performance. The sealing assembly 7 further prevents moisture from entering from the end of the terminal assembly 22.

[0043] See Figure 1 , Figure 2 and Figure 6 As shown, the outer casing assembly 1 includes an upper casing 11 and a lower casing 12. A fork plate 101 is formed at one end of the upper casing 11 near the lower casing 12. The fork plate 101 is elastic and has a Y-shaped structure, allowing it to have a certain elastic deformation capability when engaging with other components, thus better adapting to different connection requirements. An extension plate 102 is formed at one end of the lower casing 12 near the upper casing 11. The extension plate 102 is rigid, and the extension plate 102 and the fork plate 101 are connected internally through a plug-in connection. The upper casing 11 and the lower casing 12 are externally connected by locking fasteners 15. Six or eight locking fasteners 15 are arranged circumferentially. Each locking fastener 15 includes a locking piece 151 mounted on the outer wall of the lower casing 12 and a retaining ring 152 mounted on the outer wall of the upper casing 11. The retaining ring 152 and the locking piece 151 are fastened together to ensure the stability of the connection between the upper casing 11 and the lower casing 12.

[0044] See Figure 2 and Figure 4As shown, the inner core assembly 2 is installed inside the cavity 13, including a molding base 21 and a terminal assembly 22 installed in the mounting channel. The molding base 21 consists of an upper base 211 with a polygonal structure and a lower base 212 integrally formed on the upper base 211. The molding base 21 is quadrilateral, hexagonal or octagonal, depending on the cavity formed by the upper shell 11 and the lower shell 12. Its mounting channel is used for the terminal assembly 22 to pass through. The side of the upper base 211 forms a guide surface that corresponds to the shape and specifications of the inner sidewall of the cavity 13, which facilitates the accurate installation of the molding base 21 inside the cavity 13. The terminal assembly 22 includes a main terminal 221 and a secondary terminal 222. The secondary terminals 222 are arranged around the main terminals 221. The angle between adjacent secondary terminals 222 is acute or obtuse. This layout can improve the connection stability of the terminal assembly 22.

[0045] See Figure 5 As shown, both the main terminal 221 and the auxiliary terminal 222 have a rod portion 2200, a torque portion 2201, and a guide portion 2202, which are sequentially injection molded. The guide portions 2202 of the main terminal 221 and the auxiliary terminal 222 are arranged in parallel, with the main terminal 221 at the center and four auxiliary terminals 222 arranged around it. The torsion angle of the torque portion 2201 of the main terminal 221 is greater than that of the torque portion 2201 of the auxiliary terminals 222. The cross-sectional surface of the rod portion 2200 of the main terminal 221 is larger than that of the rod portion 2200 of the auxiliary terminals 222. The side of the main terminal 221 forms a chamfered surface, which fits against the inner wall of the mounting channel. The angled surface formed by the rod portions 2200 of the main terminal 221 and the auxiliary terminal 222 abuts against the upper housing 11. For example, the main terminal 221 and the secondary terminal 222 can be made of materials with good conductivity, such as copper alloys, to ensure the stability of signal transmission. See also Figure 7 As shown, a recessed groove 202 is provided on the end face of the main terminal 221 / sub-terminal 222 facing the bottom wall of the mounting channel. A protrusion 201 matching the recessed groove 202 is formed on the end face of the mounting channel facing the main terminal 221 / sub-terminal 222. The cross-section of the protrusion 201 is spherical, or it can be arc-shaped or conical. The protrusion and the recessed groove are positioned and matched with each other to improve the stability of the installation.

[0046] See Figure 9As shown, a transverse channel 3 and a longitudinal channel 4 are formed inside the lower housing 12. The transverse channel 3 and the longitudinal channel 4 are connected. A booster assembly 5 is arranged in the transverse channel 3, and an airtight assembly 6 is arranged in the longitudinal channel 4. The booster assembly 5 includes a first wedge 51 integrally formed at the bottom of the forming base 21, a second wedge 52 that cooperates with the first wedge 51 and is installed in the transverse channel 3, and a telescopic rod 53 installed on the side of the second wedge 52 away from the first wedge 51. The second wedge 52, the upper housing 11, and the airtight assembly 6 together form a sealed space. The second wedge 52 moves along the transverse channel 3 so that the airtight assembly 6 and the second wedge 52 are squeezed together or moved away from each other. The second wedge 52 can always maintain a sealing effect during the movement. The telescopic rod 53 can be a spring or a hydraulic rod, etc. The airtight assembly 6 includes a plastic volume 61 arranged in the longitudinal channel 4, an elastic one-way valve 62 installed at the input end of the plastic volume 61, and an output end of the plastic volume 61 connected to a cavity 63 formed in the fork plate 101. The input end of the plastic volume 61 located in the lower housing 12 is also provided with a return pipe 64, and the return pipe 64 extends out of the side of the lower housing 12 and is also provided with a pressure relief valve 65 for controlling its opening and closing. When the molding seat 21 is subjected to force and abuts against the pusher assembly 5, the pusher assembly 5 squeezes the airtight assembly 6, making the connection between the lower housing 12 and the upper housing 11 close together; when the pressure applied by the molding seat 21 decreases or disappears, the airtight assembly 6 drives the connection between the lower housing 12 and the upper housing 11 to separate.

[0047] See Figure 8 As shown, the sealing components 7 are respectively arranged at the ends of the terminal components 22 in the upper housing 11 and the lower housing 12, including a first sealing ring 71 and a second sealing ring 72. The first sealing ring 71 is installed on the terminal component 22 located in the lower housing 12, and the second sealing ring 72 is installed on the terminal component 22 located in the upper housing 11, for sealing the end connection of the terminal component 22 and preventing moisture from entering from the end of the terminal component 22; for example, the first sealing ring 71 and the second sealing ring 72 can be made of materials with good sealing performance such as rubber.

[0048] join Figure 9As shown, a telescopic component for resetting the second wedge 52 is also provided in the transverse channel 3. One end of the telescopic component is connected to the second wedge 52, and the other end of the telescopic component is connected to the inner wall of the transverse channel 3. The end of the second wedge 52 away from the first wedge 51 is elastic. When the second wedge 52 moves along the transverse channel 3 toward the plastic volume 61, the second wedge 52 squeezes the plastic volume 61 to open the elastic one-way valve 62. The medium in the longitudinal channel 4 is pressed into the cavity 63 in the fork plate 101, and the fork plates 101 on both sides abut against the extension plate 102. When the second wedge 52 moves away from the plastic volume 61, the pressure relief valve 65 drives the pressure difference in the plastic volume 61 to balance, the elastic one-way valve 62 closes, and the abutting action of the fork plate 101 toward the extension plate 102 gradually decreases until it disappears, thereby facilitating the separation of the upper shell 11 and the lower shell 12.

[0049] The implementation principle of this embodiment is as follows: This novel waterproof connector, through the split design of the outer shell assembly 1, facilitates the assembly and maintenance of the connector and ensures the stability of signal transmission; the force is applied to the molding base 21, and the first wedge 51 at its bottom pushes against the second wedge 52, causing the second wedge 52 to compress the plastic volume 61. The elastic one-way valve 62 allows the medium to flow into the cavity 63, causing the cavity 63 in the fork plate 101 to move closer to the extension plate 102, and the upper shell 11 and the lower shell 12 to abut against each other; conversely, the telescopic rod 53 is used to push the second wedge 52 to move towards the first wedge 51, and the pressure relief valve 65 is at this time In the open state, the second wedge 52 in the transverse channel 3 is easily reset, the cavity 63 is in the restored state, the contact between the extension plate 102 and the fork plate 101 gradually decreases, the upper shell 11 and the lower shell 12 are disassembled and separated, and the connection state of the upper shell 11 and the lower shell 12 is adjusted according to the force of the molding seat 21, which enhances the waterproof performance; the sealing component 7 further prevents moisture from entering from the end of the terminal component 22, effectively solving the defects of existing waterproofing methods such as easy wear and aging of the sealing ring, difficulty in repairing the potting compound, and easy peeling of the waterproof coating, improving the reliability and stability of the connector and extending its service life. Example

[0050] The novel waterproof connector manufacturing process provided in this application includes the following steps: S1. Prepare raw materials, bend the main terminal 221 and the auxiliary terminal 222 according to specifications, and injection mold them to form the molded base 21. In this step, it is necessary to select suitable raw materials, such as copper alloys and other materials with good conductivity, for making the main terminal 221 and the auxiliary terminal 222, and plastics and other materials for injection molding the base 21. Use bending equipment to bend the main terminal 221 and the auxiliary terminal 222 to meet the specifications, and then use an injection molding machine to injection mold the base 21.

[0051] S2. Electroplating treatment of the main terminal 221 and the auxiliary terminal 222, and chamfering, roughening and passivation treatment of the guide part 2202. Electroplating treatment can improve the oxidation resistance and conductivity of the main terminal 221 and the auxiliary terminal 222, and chamfering, roughening and passivation treatment of the guide part 2202 can improve its guiding performance and wear resistance. During the electroplating process, it is necessary to control parameters such as the composition and concentration of the electroplating solution, electroplating time and current to ensure the electroplating quality. The chamfering, roughening and passivation treatment of the guide part 2202 can be performed using appropriate processing equipment.

[0052] S3. The main terminal 221 and the auxiliary terminal 222 are pre-installed on the molding base 21 through the installation channel. After injection molding, cooling and demolding, the upper shell 11 and the lower shell 12 are formed. The inner core component 2 is then pre-installed in the cavity 13 formed by the upper shell 11 and the lower shell 12. When pre-installing the main terminal 221 and the auxiliary terminal 222, it is necessary to ensure that their installation positions are accurate. Then, the upper shell 11 and the lower shell 12 are formed by injection molding. After injection molding, cooling and demolding are performed to pre-install the inner core component 2 in the cavity 13.

[0053] S4. The molding seat 21 and the upper housing 11 are aligned and assembled towards the lower housing 12. The molding seat 21 is pressed against the bottom of the cavity 13. The first wedge 51 abuts against the second wedge and moves along the transverse channel 3, compressing the plastic volume 61. The elastic one-way valve 62 is opened, and the medium flows through the longitudinal channel 4 towards the cavity 63. The Y-shaped insert plate abuts against the extension plate 102 to ensure the precise positioning of the inner core assembly 2 and the cavity 13. The upper housing 11 and the lower housing 12 initially form a waterproof seal. During the alignment and assembly process, it is necessary to ensure the accurate position of the molding seat 21, the upper housing 11, and the lower housing 12. When pressing the molding seat 21, appropriate pressure should be applied to ensure that the first wedge 51 can effectively abut against the second wedge.

[0054] S5, the retaining ring 152 of the upper housing 11 and the locking piece 151 of the lower housing 12 are locked together to achieve a tight and stable fit on the connector axis. During the locking process, it is necessary to ensure that the retaining ring 152 and the locking piece 151 fit tightly to ensure the connection stability of the connector.

[0055] S6. The first sealing ring 71 and the second sealing ring 72 seal the ends of the upper housing 11 and the lower housing 12, forming a secondary waterproof seal. When installing the first sealing ring 71 and the second sealing ring 72, it is necessary to ensure that their installation positions are accurate and that their sealing performance is good.

[0056] The implementation principle of this embodiment is as follows: the manufacturing process involves multiple steps to ensure the accurate installation and connection of each component of the new waterproof connector, thereby guaranteeing the waterproof performance, connection stability and reliability of the connector; for example, electroplating improves the performance of the terminals, the cooperation of the airtight component 6 achieves a tight connection between the upper shell 11 and the lower shell 12, the sealing component 7 further enhances the waterproof effect, and the overall process improves the quality and service life of the connector, solving the problems existing in the existing manufacturing process, such as poor sealing performance and difficult maintenance.

[0057] Unless otherwise defined, the technical or scientific terms used in this application shall have the ordinary meaning understood by one of ordinary skill in the art to which this application pertains. The terms "first," "second," "third," and similar terms used in this application specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. The terms "an" or "a" and similar terms do not indicate a quantity limitation, but rather indicate the presence of at least one. The terms "comprising" or "including" and similar terms mean that the elements or objects preceding "comprising" or "including" encompass the elements or objects listed following "comprising" or "including" and their equivalents, and do not exclude other elements or objects. "Above," "below," "left," "right," etc., are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0058] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A novel waterproof connector, characterized in that, include: The outer shell assembly (1) has a split structure, having an upper shell (11) and a lower shell (12), the upper shell (11) and the lower shell (12) forming a cavity (13), the upper shell (11) and the lower shell (12) being internally connected by a connector, the lower shell (12) having a through hole (14) and the through hole (14) communicating with the cavity (13), and the upper shell (11) and the lower shell (12) being externally connected by a locking fastener (15); The inner core assembly (2) is installed in the cavity (13). The inner core assembly (2) has an installation channel and is connected to the through hole (14). The inner core assembly (2) includes a molding seat (21) and a terminal assembly (22) installed in the installation channel. The lower housing (12) has a transverse channel (3) and a longitudinal channel (4) connected to each other. A booster assembly (5) is arranged in the transverse channel (3), and an airtight assembly (6) for the upper housing (11) and the lower housing (12) to be attached or detached is arranged in the longitudinal channel (4). The end of the booster assembly (5) away from the airtight assembly (6) is in contact with the molding seat (21). The molding seat (21) is subjected to force and abuts against the booster assembly (5). The booster assembly (5) squeezes the airtight assembly (6) to make the connection between the lower housing (12) and the upper housing (11) fit tightly. The pressure applied by the molding seat (21) decreases or disappears, and the airtight assembly (6) drives the connection between the lower housing (12) and the upper housing (11) to separate. A sealing assembly (7) is arranged at the end of the terminal assembly (22) in the upper housing (11) and the lower housing (12) respectively, for sealing the end connection of the terminal assembly (22).

2. The novel waterproof connector according to claim 1, characterized in that: The connector includes a fork plate (101) formed on the upper housing (11) near the lower housing (12) and an extension plate (102) formed on the lower housing (12) near the upper housing (11). The fork plate (101) is elastic and the extension plate (102) is rigid. The fork plate (101) has a Y-shaped structure and the extension plate (102) and the fork plate (101) are connected by a plug-in joint.

3. The novel waterproof connector according to claim 1, characterized in that: The terminal assembly (22) includes a main terminal (221) and a secondary terminal (222). The secondary terminals (222) are arranged around the main terminal (221), and the angle between adjacent secondary terminals (222) is an acute or obtuse angle. Both the main terminal (221) and the secondary terminal (222) have a rod portion (2200), a torque portion (2201), and a guide portion (2202). The rod portion (2200), the torque portion (2201), and the guide portion (2202) are sequentially injection molded. The guide portions (2202) of the main terminal (221) and the guide portions (2202) of the secondary terminal (222) are arranged in parallel. The torsion angle of the torque portion (2201) of the main terminal (221) is greater than that of the torque portion (2201) of the secondary terminal (222). The torsion angle is such that the cross-sectional surface of the rod portion (2200) of the main terminal (221) is larger than that of the rod portion (2200) of the sub-terminal (222). The side portion of the main terminal (221) forms a chamfered surface, which fits against the inner wall of the mounting channel. The angled surface formed by the rod portion (2200) of the main terminal (221) / sub-terminal (222) abuts against the upper housing (11). The end face of the main terminal (221) / sub-terminal (222) facing the bottom wall of the mounting channel is provided with a recessed groove (202). The end face of the mounting channel facing the main terminal (221) / sub-terminal (222) is provided with a protrusion (201) that matches the recessed groove (202). The cross-section of the protrusion (201) is any one of spherical, arc-shaped, and conical.

4. A novel waterproof connector according to claim 1, characterized in that: The molding base (21) consists of an upper base (211) with a polygonal structure and a lower base (212) integrally formed on the upper base (211). The side of the upper base (211) forms a guide surface, which corresponds to the shape and specifications of the inner wall of the cavity (13).

5. A novel waterproof connector according to claim 2, characterized in that: The booster assembly (5) includes a first wedge (51) integrally formed on the bottom of the molding base (21), a second wedge (52) that cooperates with the first wedge (51) and is installed in the transverse channel (3), and a telescopic rod (53) installed on the side of the second wedge (52) away from the first wedge (51). The second wedge (52), the upper shell (11) and the airtight assembly (6) together form a sealed space. The second wedge (52) moves along the transverse channel (3) to make the airtight assembly (6) and the second wedge (52) squeeze or move away from each other.

6. A novel waterproof connector according to claim 5, characterized in that: The airtight assembly (6) includes a plastic volume (61) arranged in the longitudinal channel (4), an elastic one-way valve (62) installed at the input end of the plastic volume (61), and the output end of the plastic volume (61) connected to a cavity (63) formed in the fork plate (101). The input end of the plastic volume (61) located in the lower housing (12) is also provided with a return pipe (64), and the return pipe (64) is provided with a pressure relief valve (65) for controlling its opening and closing through the side of the lower housing (12).

7. A novel waterproof connector according to claim 1, characterized in that: The locking fastener (15) includes a locking piece (151) installed on the outer side wall of the lower housing (12) and a buckle (152) installed on the outer side wall of the upper housing (11), wherein the buckle (152) and the locking piece (151) are fastened together.

8. A novel waterproof connector according to claim 1, characterized in that: The sealing assembly (7) includes a first sealing ring (71) and a second sealing ring (72). The first sealing ring (71) is mounted on the terminal assembly (22) located inside the lower housing (12), and the second sealing ring (72) is mounted on the terminal assembly (22) located in the upper housing (11).

9. A novel waterproof connector according to claim 6, characterized in that: The transverse channel (3) is also provided with a telescopic member for resetting the second wedge (52). One end of the telescopic member is connected to the second wedge (52), and the other end of the telescopic member is connected to the inner wall of the transverse channel (3). The end of the second wedge (52) away from the first wedge (51) is elastic. The second wedge (52) moves along the transverse channel (3) toward the plastic volume (61), and the second wedge (52) squeezes the plastic volume (61) to make the elastic When the check valve (62) is turned on, the medium in the longitudinal channel (4) is pressed into the cavity (63) in the fork plate (101), and the fork plates (101) on both sides abut against each other in the extension plate (102); the second wedge (52) moves away from the plastic volume (61), the pressure relief valve (65) drives the pressure difference in the plastic volume (61) to balance, the elastic check valve (62) closes, and the abutting effect of the fork plate (101) towards the extension plate (102) gradually decreases.

10. A novel waterproof connector manufacturing process, employing the novel waterproof connector described in claims 1-9, characterized in that, Includes the following steps: Step 1: Prepare raw materials, bend the main terminal (221) and the auxiliary terminal (222) according to the specifications, and injection mold to form the molding base (21); Step 2: Electroplating treatment of the main terminal (221) and the auxiliary terminal (222), and chamfering, roughening and passivation treatment of the guide part (2202); Step 3: The main terminal (221) and the auxiliary terminal (222) are pre-installed on the molding base (21) in sequence through the installation channel. The upper shell (11) and the lower shell (12) are formed by injection molding, cooling and demolding. The inner core assembly (2) is pre-installed in the upper shell (11) and the lower shell (12) to form the cavity (13). Step 4: The molding seat (21) and the upper shell (11) are aligned and assembled with the lower shell (12). The molding seat (21) is pressed against the bottom of the cavity (13). The first wedge (51) abuts against the second wedge and moves along the transverse channel (3) to compress the plastic volume (61). The elastic one-way valve (62) is opened. The medium flows through the longitudinal channel (4) in the direction toward the bladder (63). The Y-shaped structure insert plate abuts against the extension plate (102) to ensure that the inner core assembly (2) and the cavity (13) are accurately positioned. The upper shell (11) and the lower shell (12) initially form a waterproof seal. Step 5: The retaining ring (152) of the upper housing (11) and the locking piece (151) of the lower housing (12) are locked together to achieve a tight and stable fit on the connector axis; Step 6: The first sealing ring (71) and the second sealing ring (72) seal the ends of the upper housing (11) and the lower housing (12) to form a secondary waterproof seal.

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