Primer-Treated Joint Connector Structure for Waterproof Resin Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing joint connectors for electric wires in vehicles are prone to water ingress due to gaps formed between the connection member and the resin housing, compromising their waterproof integrity.
Innovation Solution
A joint connector design featuring a conductive metal ground terminal member with a primer treatment portion and a housing, where the terminal member is integrally formed with a crank-shaped bent portion and a primer treatment applied to its outer surface, combined with a specific molding process using a gate positioned to minimize resin flow impact on the primer, ensuring close contact and preventing gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If integral molding is performed to connect the connection member and housing, then manufacturing efficiency is improved, but gaps may form between the connection member and resin housing due to thermal expansion or environmental conditions
Solution Approach 1:
A primer treatment portion is applied in advance to the outer peripheral surface of the connection member at the position where close contact with the housing is required. This preliminary action ensures that when integral molding is performed, the resin can properly adhere to the metal surface, preventing gap formation and maintaining waterproof integrity while preserving manufacturing efficiency.
Solution Approach 2:
The primer treatment portion acts as an intermediary substance between the metal connection member and the resin housing. This intermediate layer improves adhesion and ensures reliable close contact, resolving the contradiction between efficient integral molding and waterproof reliability by facilitating proper bonding between the two materials.
2Ease of manufacture
If the outer peripheral surface of the connection member is left untreated, then manufacturing process is simplified, but gaps form between the connection member and resin housing compromising waterproofing
Solution Approach 1:
The primer treatment is applied in advance to the specific outer peripheral surface of the connection member before integral molding. This preliminary treatment ensures proper adhesion between the metal and resin, preventing gap formation and maintaining waterproof integrity, while the treatment is applied only to the necessary area to maintain manufacturing simplicity.
Solution Approach 2:
The primer treatment portion is applied locally and selectively to the outer peripheral surface of the connection member where close contact with the housing is required, rather than treating the entire surface. This localized approach maintains manufacturing simplicity while ensuring waterproof integrity at the critical interface between the connection member and housing.
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 design effectively prevents water ingress by maintaining close contact between the resin and metal surfaces, ensuring the connector's waterproof integrity even under varying environmental conditions.
Implementation Method 1
a primer treatment portion formed by applying a primer onto the ground terminal member
Implementation Method 2
molding the housing by filling the mold with a molten resin from a gate disposed at a position facing the terminal connection portion in the mold
Data Source
AI summary
There is provided a joint connector including: a ground terminal member made of a conductive metal, and configured by integrally forming a plate-shaped fixing portion fixed to a ground portion, the body horizontal plate portion extending from the plate-shaped fixing portion, the body rising plate portion formed by bending the body horizontal plate portion in a rising direction at a bent portion, the terminal connection portion provided above the body rising plate portion, and the crank-shaped bent portion bent in a crank shape near the terminal connection portion in the body rising plate portion; a housing to which the ground terminal member is insert-molded; and a primer treatment portion applied to an outer peripheral surface of the body rising plate portion on a side of the body horizontal plate portion with respect to the crank-shaped bent portion.