Waterproof Electrical Connector Insert-Molded Insulator Seal
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Solution Overview
Problem
Existing waterproof electrical connectors are inadequate in sealing the rear end of the housing and shell, allowing fluid or gas to damage the connector, and the insulator formed by glue is too soft to ensure effective waterproofing and dust prevention.
Innovation Solution
An electrical connector design featuring an insulative housing with terminals having soldering portions, a metallic shielding shell with a tail portion and grooves, and an insulator insert-molded to seal the rear end, using a die-casting process for the shielding shell and over-molding to secure the components together, ensuring a robust and effective seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If glue is used to seal the gap between the shell and insulator, then the assembly is simple, but the waterproof sealing effectiveness is insufficient due to the softness of the insulator
Solution Approach 1:
The patent changes the physical state and mechanical properties of the insulator by replacing soft glue with a hard insulating material formed through injection molding. This parameter change in material hardness and structural rigidity enables the insulator to maintain effective waterproof sealing while being assembled with the shell through positioning structures like protrusions and grooves.
2Ease of operation
If the insulator is made soft for assembly, then ease of assembly is improved, but the ability to control filter and ensure waterproofing is compromised
Solution Approach 1:
The patent incorporates positioning structures such as protrusions and grooves in advance during the injection molding process. These preliminary structural features guide the assembly process and ensure precise alignment between the insulator and shell, maintaining manufacturing precision without requiring the insulator material to be soft for assembly.
Data Source
AI summary
An electrical connector includes an insulative housing, a number of terminals retained in the insulative housing, a shielding shell attached to the insulative housing, and an insulator insert-molded with a rear end of the shielding shell. The terminals have a number of soldering portions extending out of a rear surface of the insulative housing. The shielding shell has a tail portion located at a rear end thereof. The insulator at least wraps partly an external surface of the tail portion to seal up a rear end of the insulative housing and extend the soldering portions of the terminals through the insulator to expose a rear surface thereof.