Insert-to-Housing Fusion Sealing for Waterproof Overmolding
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Solution Overview
Problem
Existing over-molding processes fail to create a tight, waterproof housing for electrical components due to delamination issues and the inability to over-mold the touchpoint of the contact element, leading to potential exposure to liquids and particles.
Innovation Solution
The method involves welding the insert to the over-molded housing using a radiation source to create a fusion zone, which seals the insert from the touchpoint and provides a stable, waterproof connection even under harsh environmental conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the insert is held by a contact element during over-molding, then the insert can be positioned in the molding tool, but the touchpoint of the contact element cannot be over-molded leading to delamination and leakage
Solution Approach 1:
The solution separates the positioning function (contact element during molding) from the sealing function (welding after molding). The contact element is removed after molding, and a welding process is applied separately to create the seal at the touchpoint region, allowing each function to be optimized independently
Solution Approach 2:
The insert is first positioned using the contact element during the over-molding process, then the contact element is removed and welding is performed subsequently. This preliminary positioning followed by post-processing welding allows the sealing to be applied after the structural molding is complete
2Object-affected harmful factors
If the insert is over-molded with housing material, then the electrical component is enclosed and protected, but delamination occurs between the insert and housing leading to media penetration
Solution Approach 1:
The welding process changes the physical parameters (temperature, pressure) at the interface between insert and housing to create a fusion zone. This thermal and mechanical parameter change transforms the bonding mechanism from adhesive to cohesive, eliminating delamination
Solution Approach 2:
The solution creates a composite structure with three distinct zones: the insert material, the over-molded housing material, and the fusion zone where they are welded together. This composite approach allows each material to maintain its properties while creating a strong bonded interface
3Productivity
If conventional over-molding processes are used, then mass production is economically feasible, but the housing is not tight enough for harsh environmental conditions
Solution Approach 1:
The solution merges two processes: the conventional over-molding process for mass production and a subsequent welding process for sealing. By combining these processes in sequence, the patent achieves both economic manufacturability and high sealing performance required for harsh environments
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 solution effectively seals the insert against media such as water and particles, ensuring the electrical component remains protected and functional over its lifetime, even in harsh environments.
Implementation Method 1
welding an insert to an over-molded housing to form a fusion zone for joining the insert and the over-molded housing
Implementation Method 2
using a radiation source for welding. This allows for laser or electron beam welding
Implementation Method 3
the reversible material is to be melt when heated by the radiation source
Implementation Method 4
The beam provides a concentrated radian energy source, allowing for narrow, deep welds and high welding rates
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Method for sealing of an insert (100) against media in an over-molded housing (200). The method comprises the steps of: holding (S3) the insert at a touchpoint (152) to place the insert in a molding tool (300); Over-molding the insert with a molding material to enclose to the insert with the over-molded housing (200); and Welding, using a radiation source (400), the insert to the over-molded housing to form a fusion zone (130) for joining the insert (100) and the over-molded housing (200), wherein the fusion zone comprises a reversible material, the reversible material to be melt when heated by the radiation source and to seal, when cured, the insert from the contact element.