Plug Waterproofing via Terminal Division Plate
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Solution Overview
Problem
Conventional plugs have insufficient waterproofing due to incomplete sealing between the cover and terminal components, allowing water vapor to enter the seat.
Innovation Solution
The plug incorporates a division plate within the terminal's tube portion to separate the chamber into two spaces, with the cover filling the second space and the division plate preventing water vapor from entering the first space, enhancing the waterproof effect through double protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cover is mounted on the seat to close the second opening of the terminal, then the terminal connector is assembled, but the cover cannot completely abut the inner surface of the tube portion, resulting in insufficient waterproofing
Solution Approach 1:
The chamber is divided into a first space and a second space by the division plate. The cover only needs to fill and seal the second space, while the division plate seals the interface between the first space and the second space. This segmentation allows the cover to achieve complete sealing without requiring complex structures, as it only needs to abut the division plate rather than the entire inner surface of the tube portion.
Solution Approach 2:
The division plate acts as an intermediary element between the cover and the tube portion inner surface. The cover abuts the division plate to seal the second space, while the division plate itself seals the interface with the first space. This intermediary structure simplifies the sealing mechanism compared to requiring the cover to directly seal the entire chamber.
2Ease of manufacture
If the cover overmolds the terminal to close the second opening, then the terminal connector is assembled, but water vapor easily enters the seat via the terminal connector
Solution Approach 1:
The sealing function is segmented between the cover and the division plate. The cover's overmolding process remains simple (maintaining ease of manufacture), while the division plate provides the additional sealing function needed to prevent water vapor entry. This segmentation allows the manufacturing process to remain simple while achieving improved waterproofing.
3Manufacturing precision
If the second opening is closed by overmolding the cover, then the terminal connector is sealed, but the second opening is not completely sealed due to incomplete abutment
Solution Approach 1:
The sealing task is divided into two parts: the cover seals the second opening by abutting the division plate, and the division plate seals the interface between the first and second spaces. This segmentation improves sealing precision because the cover only needs to achieve precise abutment with the division plate, not with the entire tube portion inner surface, reducing the complexity requirement.
Data Source
AI summary
A plug has a seat, a circuit board disposed in the seat, and a waterproof terminal connector disposed on the seat. The waterproof terminal connector has two terminals and a cover. Each one of the terminals has a tube portion, a division plate, and a connecting portion. The tube portion has a chamber formed in the tube portion. The division plate is formed in the tube portion for dividing the chamber of the tube portion into a first space and a second space. The connecting portion is formed on the tube portion. The cover is formed by an overmolding process, is connected to the two terminals and fills the second spaces of the two terminals. Water vapor can be stopped by the division plate for improving the waterproof effect of the plug.