Bag-Molded Waterproof Connector for Retrofit Battery Modules
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Solution Overview
Problem
Existing battery modules lack waterproof connectors, making them unsuitable for use in harsh environmental conditions, and replacing non-waterproof connectors with waterproof ones is challenging due to structural differences.
Innovation Solution
A waterproof connector is created by adding a bag molding member made of waterproof material, injection molded around the rear surface of the connector housing, to seal the opening portion and prevent moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an existing non-waterproof connector is replaced with a new waterproof connector, then waterproof performance is improved, but installation difficulty increases due to structural differences
Solution Approach 1:
The patent combines the existing non-waterproof connector structure with an additional waterproofing component (molded member) to create a hybrid structure that maintains compatibility with existing installations while adding waterproof functionality. The molded member is injected onto the existing connector body, merging the old and new structural elements into a unified waterproof connector assembly.
Solution Approach 2:
The waterproofing structure is formed by injecting material onto the existing connector before final assembly and installation. This preliminary action of adding the waterproof layer beforehand allows the connector to be retrofitted without requiring complete disassembly or complex installation procedures, maintaining ease of installation while achieving waterproof performance.
2Reliability
If a waterproof connector is designed from scratch, then waterproof performance is improved, but manufacturing complexity increases
Solution Approach 1:
The connector is divided into two functional segments: the original non-waterproof connector structure and the added waterproof molded member. This segmentation allows the existing connector design to be preserved while only the necessary waterproofing portion is added, reducing overall structural complexity compared to redesigning the entire connector.
Solution Approach 2:
The molded waterproof member serves multiple functions simultaneously: it seals the opening portion to prevent moisture ingress, provides structural support for the waterproof seal, and maintains compatibility with the existing connector interface. This multi-functionality reduces the need for additional separate components, simplifying the overall structure.
3Reliability
If the opening portion of the connector housing is sealed, then waterproof performance is improved, but electrical connection accessibility is reduced
Solution Approach 1:
The waterproofing is applied locally only at the opening portion where moisture ingress is most likely to occur, rather than sealing the entire connector housing. The molded member specifically targets the vulnerable opening area while leaving the electrical connection areas accessible, achieving waterproof performance without compromising terminal accessibility.
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 existing non-waterproof connectors to be retrofitted with waterproof functionality, enhancing their suitability for use in wet or humid environments without the need for structural changes.
Implementation Method 1
a bag molding member which is an injection molded product, the bag molding member surrounding and sealing the opening portion
Data Source
AI summary
A waterproof connector includes at least one connector terminal, a connector housing including a connecting portion formed on a front surface to connect another connector and an opening portion formed on a rear surface to form an open space through which the connector terminal is exposed, a connector cable connected to a side of the connector terminal exposed through the opening portion, and a bag molding member which is an injection molded product, the bag molding member surrounding and sealing the opening portion.