Connector Waterproof Block Injection Molding
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Solution Overview
Problem
Conventional methods for manufacturing waterproof connectors through spraying or dispensing glues are costly and inefficient, with issues including clogged sprayers, high viscosity glue waste, air bubbles, and the need for expensive equipment and baking processes.
Innovation Solution
A method involving the assembly of a terminal module with a hollow area and terminals, followed by the injection-molding of a waterproof block into the hollow area to encase the terminals, creating a precise waterproof structure without the need for baking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spraying or dispensing glues is used to form waterproof structures, then waterproofing function is achieved, but manufacturing cost increases and production efficiency decreases
Solution Approach 1:
The patent replaces the mechanical spraying/dispensing system with an inject-molding system. The waterproof block is formed by injecting material into a cavity within the housing, eliminating the need for spray nozzles, dispensers, and manual gluing operations. This substitution of the mechanical system achieves waterproofing while significantly improving production efficiency and reducing manufacturing costs.
2Reliability
If spraying equipment is used, then waterproofing is achieved, but equipment cost and maintenance cost increase
Solution Approach 1:
The patent eliminates expensive, complex spraying equipment by using a simpler inject-molding process. The waterproof block is formed directly within the housing cavity through injection molding, which uses standard molding equipment rather than specialized spray systems. This approach reduces both initial equipment investment and ongoing maintenance costs.
3Reliability
If spraying or dispensing is used, then waterproofing is achieved, but manufacturing precision decreases due to positioning difficulties
Solution Approach 1:
The patent incorporates the waterproof block as an integrated part of the housing structure through inject-molding. The waterproof material is molded directly into the housing cavity in advance, ensuring precise positioning and integration with the housing. This preliminary formation of the waterproof structure eliminates positioning errors that would occur with post-assembly spraying or dispensing methods.
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 approach reduces production costs and time by eliminating the baking process and ensuring precise positioning of the waterproof structure, enhancing manufacturing efficiency and reducing waste.
Implementation Method 1
thirdly inject-molding a waterproof block into the hollow area, wherein the waterproof block encases the plurality of the terminals disposed in the hollow area
Data Source
AI summary
The present disclosure provides a method for manufacturing connector, comprising steps of: Obtaining a terminal module comprising a terminal body and a plurality of terminals, wherein the terminal body comprises an interface part, a hollow area, and an electrical connecting part, the hollow area is disposed between the interface part and the electrical connecting part, the plurality of terminals is disposed on the terminal body, each terminal passes through the interface part, the hollow area, and the electrical connecting part. Assembling a housing on the terminal module, wherein the hollow area passed by the plurality of the terminals is exposed from the housing. Inject-molding a waterproof block into the hollow area, wherein the waterproof block encases the plurality of the terminals disposed in the hollow area, the waterproof block is disposed between the interface part and the electrical connecting part.