Pre-Molded Waterproof Connector Structure Without Potting
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Solution Overview
Problem
Existing connectors for vehicles lack a simple and effective waterproof structure, requiring additional processes like potting with elastic materials for airtightness, which complicates manufacturing and increases costs.
Innovation Solution
A connector design featuring a pre-mold made of ThermoPlastic Elastomer (TPE) material, through which connector pins protrude, and a housing that surrounds the pre-mold, forming a waterproof structure by injection-molding without potting, with protrusions and chamfered edges for secure coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If potting with elastic material is used to achieve waterproofing, then waterproof performance is improved, but manufacturing complexity increases
Solution Approach 1:
The connector is divided into two separate molding processes: a pre-mold containing the connector pins, and a housing molded around the pre-mold. This segmentation allows each component to be optimized independently while achieving waterproofing through the integrated structure without requiring additional potting materials or processes.
Solution Approach 2:
The waterproofing function is merged into the housing structure itself through insert injection molding. The housing is molded directly around the pre-mold, creating an integrated waterproof enclosure that combines structural support and sealing functions in a single manufacturing operation, eliminating the need for separate potting processes.
2Reliability
If potting process is applied for airtightness, then waterproof performance is improved, but manufacturing time increases
Solution Approach 1:
The pre-mold is prepared in advance with the connector pins already positioned and secured. This preliminary action allows the housing to be molded directly around the pre-assembled pre-mold in a single insert injection molding operation, eliminating the time-consuming sequential steps of applying and curing potting materials after assembly.
3Ease of manufacture
If adhesive interface is created between connector pins and mold, then manufacturing is simplified, but waterproof function is lost
Solution Approach 1:
The pre-mold acts as an intermediary component between the connector pins and the housing. It provides a molding interface that allows adhesive bonding during injection molding while simultaneously creating the waterproof seal when the housing is molded around it. This intermediary structure resolves the conflict between manufacturing simplicity and waterproof functionality.
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 achieves a waterproof structure with simplified manufacturing, reduced costs, and firm component coupling, maintaining waterproof performance under high-temperature and high-humidity conditions.
Implementation Method 1
The pre-mold may be formed of a ThermoPlastic Elastomer (TPE) material
Implementation Method 2
The housing may be in direct contact with and adhered to all surfaces of the pre-mold
Data Source
AI summary
A connector may include: at least one electrically conductive connector pin; a pre-mold formed such that the connector pin penetrates the pre-mold and both ends of the connector pin respectively protrude from a first surface and a second surface of the pre-mold; and a housing configured to expose at least one end of the connector pin to outside and accommodate the pre-mold therein, wherein the housing has a shape surrounding the pre-mold in all directions.