Connector Sealing via Pre-bent Lead Section and Guide Wall
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Solution Overview
Problem
Existing connectors face challenges in assembling the connector terminal with a bent lead section into the connector housing without increasing costs, while preventing foreign matter ingress and maintaining sealing, especially when thermal contraction and expansion occur, and ensuring precise location and stress reduction on the substrate.
Innovation Solution
A connector design where the lead section is bent before outsert-molding, allowing direct contact with the guide wall for sealing and reduced stress, enabling assembly without enlarging the housing opening, thus preventing foreign matter entry and enhancing heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the lead section is bent after outsert-molding, then the bending process can be performed, but cracks occur in the connector housing and location precision deteriorates
Solution Approach 1:
The lead section is bent before the outsert-molding process, not after. This preliminary bending action prevents subsequent cracking and maintains location precision, as the housing resin is not yet hardened and can accommodate the bent shape without stress concentration that would cause cracks.
Solution Approach 2:
The conventional sequence is inverted: instead of bending after molding, the bending is performed before molding. This reversal of the process sequence eliminates the harmful effects of bending hardened resin while achieving the same functional outcome of stress mitigation.
2Ease of operation
If the housing opening is enlarged to insert the bent lead section, then assembly is possible, but foreign matter can enter and sealing is compromised
Solution Approach 1:
The lead section is bent before insertion into the housing, allowing it to be fed through the original-sized opening without enlargement. This preliminary bending action enables assembly while maintaining the sealing integrity of the housing opening.
Solution Approach 2:
The lead section is bent in a direction perpendicular to the insertion direction, allowing it to navigate through the opening and be positioned inside the housing without requiring the opening to be enlarged. This dimensional manipulation enables assembly while preserving sealing.
3Stress or pressure
If the lead section is bent to reduce stress on the substrate, then thermal stress is mitigated, but assembly complexity increases
Solution Approach 1:
The lead section is bent before outsert-molding to create stress-relief geometry. This preliminary shaping reduces thermal stress on the substrate during operation while the subsequent molding process secures the bent lead section in place, preventing assembly complexity from increasing.
Solution Approach 2:
The lead section's geometry is changed by bending it before molding, creating a configuration that reduces thermal stress. The physical state and shape parameters of the lead section are modified in advance to achieve stress mitigation without complicating the overall assembly process.
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
This design simplifies assembly, reduces stress on the substrate, prevents terminal pulling out, and improves location precision, while maintaining effective sealing and heat dissipation through direct contact with heat-conductive resin, thus enhancing connector reliability and cost-effectiveness.
Implementation Method 1
directly contacted the side surface of the bending lead section with the guide wall which is disposed on the connector housing by using a means of the insertion-press fitting or the like, improves sealing of a contact portion
Implementation Method 2
improves location precision, while maintaining effective sealing and heat dissipation through direct contact with heat-conductive resin
Data Source
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AI summary
[Problem] An obj ect of the present invention is to provide a connector comprising a connector terminal having a lead section in which a bending process is performed, which is capable of realizing a simple assembling in a low cost and prevention from entering a foreign matter to the connector housing. [Means for solving the problem] A connector housing 55 comprises a hole 57 having a minimum size that a lead section 56d of a connector terminal 56 to penetrate, and a guide wall 57d which is formed along an outer peripheral of the hole 57, and is protruded in a direction which a lead section 56d protrudes from the connector housing 55 to a bending section of the lead section 56d, wherein, by which inner walls of the guide wall is mutually and directly in contact with side surfaces of the lead section 56d over a height near a top end side of the lead section 56d in a bending section of the lead section 56d from an outer peripheral of the hole 57, a sealing structure is formed from the bending section of the lead section to an interior of the connector housing 55.