Insert-Molded Connector Housing for Waterproof Wire Sealing
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Solution Overview
Problem
Existing connectors do not provide sufficient waterproof performance, especially in certain mounting positions.
Innovation Solution
A molded connector design that includes a first and second terminal unit, each with a holder, connected to a wire, and formed through insert molding with a connector housing, using the terminal units and wire ends as insert parts, along with a sheath covering the wires to enhance waterproofness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rubber boot is used to cover the connector housing and wire, then waterproof performance is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple components (connector housing, terminal units, wires, and waterproof sealing) into a single integrated molded structure. The housing and terminal units are formed together through insert molding, eliminating the need for separate rubber boots and reducing assembly steps while maintaining waterproof performance.
Solution Approach 2:
The molded housing serves multiple functions simultaneously: it provides structural support, houses the terminal units, and creates waterproof seals. The integrated design makes the housing a multi-functional component that eliminates the need for separate waterproofing elements.
2Ease of manufacture
If separate assembly of connector components is used, then ease of manufacture is improved, but waterproofness deteriorates due to gaps between parts
Solution Approach 1:
The connector housing and terminal units are merged into a single molded structure through insert molding. This integration eliminates gaps and joints between separate parts, ensuring continuous waterproof sealing while maintaining manufacturing efficiency by forming all components in one operation.
3Reliability
If insert molding is used to form the connector housing, then waterproofness is improved by reducing gaps, but manufacturing complexity increases
Solution Approach 1:
The terminal units are prepared in advance as pre-assembled insert parts before being placed in the mold. This preliminary preparation allows the final molding process to simply encapsulate the pre-positioned components, reducing the complexity of the molding process itself while achieving the waterproof integrated structure.
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 significantly enhances waterproofness by reducing gaps between terminals and holders, inhibiting water entry, and facilitating easy wire connection, while suppressing short circuits and maintaining positional accuracy during molding.
Implementation Method 1
a connector housing formed through insert molding, using the first terminal unit, the second terminal unit, an end portion of the first wire, and an end portion of the second wire as insert parts
Data Source
AI summary
This disclosure aims to provide a technique with which the waterproofness of a connector can be enhanced. The molded connector includes: a first terminal unit that includes a first connector terminal and a first holder that holds the first connector terminal; a second terminal unit that includes a second connector terminal and a second holder that holds the second connector terminal, and is stacked on the first terminal unit; a first wire connected to the first connector terminal; a second wire connected to the second connector terminal; and a connector housing formed through insert molding, using the first terminal unit, the second terminal unit, an end portion of the first wire, and an end portion of the second wire as insert parts.