Electrical Connector Waterproof Sealing via Blocking Protrusion
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Solution Overview
Problem
Existing electrical connectors with waterproof sealing performance are unreliable due to the loosening of retaining plates under impact, leading to inadequate sealing and water ingress.
Innovation Solution
An electrical connector design featuring a metal shell with blocking protrusions and fixed plates, where the insulated body is positioned using laser welding and waterproof adhesive is applied to ensure a reliable seal, preventing water infiltration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a retaining plate is used to compress and retain the outer molded member to the shell, then the waterproof sealing is improved, but the retaining plate loosens and detaches under impact, reducing reliability
Solution Approach 1:
The patent removes the retaining plate component entirely and replaces it with an integrated blocking protrusion structure formed directly on the shell. This extraction of the problematic retaining plate eliminates the loosening and detaching issues while maintaining the sealing function through the blocking protrusion that prevents the outer molded member from moving beyond the sealing position.
Solution Approach 2:
The blocking protrusion is integrated directly into the shell structure, merging the positioning and sealing functions into a single unified component. This eliminates the separate retaining plate and its associated reliability problems, while the blocking protrusion simultaneously provides both mechanical positioning and sealing support.
2Manufacturing precision
If the insulated body is positioned using blocking protrusions and fixed plates with laser welding, then the positioning precision is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent removes the fixed plate component and its associated laser welding process, extracting this complex manufacturing step. The positioning function is instead achieved through the integrated blocking protrusion structure on the shell combined with the adhesive sealing layer, significantly simplifying the manufacturing process while maintaining positioning precision.
Solution Approach 2:
The patent replaces the mechanical laser welding fixation system with a combination of geometric blocking (blocking protrusion) and chemical adhesion (sealing adhesive). This substitution eliminates the need for precise laser welding operations while achieving equivalent or superior positioning and sealing performance.
3Reliability
If waterproof adhesive is applied to seal the rear portion of the receiving cavity, then the waterproof performance is improved, but the manufacturing process time increases
Solution Approach 1:
The patent merges the sealing adhesive application with the assembly process itself, applying the adhesive directly to the blocking protrusion or housing surface during the insertion operation. This integration eliminates separate sealing steps and allows the adhesive to be applied in a single continuous motion, maintaining high assembly speed while ensuring comprehensive waterproof sealing.
Solution Approach 2:
The sealing adhesive is pre-applied to the blocking protrusion or housing surface before the outer molded member is inserted. This preliminary action ensures that the sealing interface is already prepared, allowing for rapid assembly without requiring post-assembly sealing operations, thus maintaining high productivity while achieving reliable waterproof performance.
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 provides a reliable waterproof performance by ensuring the insulated body is securely positioned relative to the metal shell and sealing the rear portion of the receiving cavity, effectively preventing water ingress.
Implementation Method 1
a waterproof adhesive coated on the first holding portion and the rear side of the housing, so that an overall seal is achieved in a rear portion of the receiving cavity
Implementation Method 2
at least one blocking protrusion protrudes from a middle of the metal shell into the cavity... a front side of the housing is stopped by the blocking protrusion
Data Source
AI summary
An electrical connector is provided which has a reliable waterproof performance. The electrical connector has an insulated body having a housing, a plurality of conductive terminals, a metal shell, two fixed plates, and a waterproof adhesive. The plurality of conductive terminals are fixed to the insulative body. The insulated body is inserted into a cavity of the metal shell from back to front. The two fixed plates are respectively mounted on two opposite sides of the housing. Each fixed plate has a fixed portion and a holding portion bent downwardly from a rear side of the fixed portion. A rear side of the housing is held by the holding portions. The waterproof adhesive is coated on the holding portion and the rear side of the housing to form an overall seal on a rear portion of the cavity.