Roughened Inner-Shell Sealing for Water-Resistant Connectors
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Solution Overview
Problem
Conventional electrical connectors face challenges in achieving effective water resistance and manufacturing cost efficiency, particularly due to the use of molded seals which are expensive and lack flexibility in accommodating different mounting configurations.
Innovation Solution
The design incorporates an inner shell with a roughened mating end, processed using Electrical Discharge Machining (EDM) for enhanced adhesion, and an elastically deformable seal attached to the shell, which provides improved water resistance and flexibility in mounting without the need for complex convex structures, allowing for a more compact and cost-effective manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If molded seals are used in electrical connectors, then water resistance is improved, but manufacturing cost increases and flexibility in mounting configurations decreases
Solution Approach 1:
The patent removes the molded seal component entirely from the connector design. Instead of using a separate molded seal, the invention uses the inner shell itself with a roughened mating end surface that directly provides the sealing function, eliminating the need for expensive molded seals while maintaining water resistance
Solution Approach 2:
The patent changes the surface parameter of the inner shell mating end by applying a roughened surface treatment. This surface modification enables the metal shell to provide effective sealing without requiring a molded seal, thereby reducing manufacturing cost while maintaining water resistance
2Reliability
If molded seals are used in electrical connectors, then water resistance is improved, but flexibility in mounting configurations decreases
Solution Approach 1:
By removing the molded seal component, the invention eliminates the structural constraints that molded seals impose on mounting configurations. The simplified design with the roughened inner shell surface allows for greater adaptability in different mounting scenarios while maintaining effective sealing
3Reliability
If conventional sealing structures are used, then water resistance is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the sealing function into the inner shell structure itself through surface roughening. Instead of having a separate sealing component, the sealing capability is integrated directly into the metal shell's mating end surface, simplifying the overall device structure while maintaining water resistance
Solution Approach 2:
The invention uses a simple, inexpensive surface treatment on the metal shell instead of expensive molded seals. This approach prioritizes cost-effective manufacturing while achieving the necessary sealing performance
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 enhances the water resistance and service life of electrical connectors while reducing manufacturing costs by eliminating the need for molded seals and allowing for flexible mounting configurations, resulting in a more compact and effective sealing mechanism.
Implementation Method 1
The roughened portion is formed on the outer sidewall surface of the inner shell near the mating end of the inner shell. In some embodiments, the roughened portion is formed by performing electrical discharge machining (EDM) on the outer sidewall surface of the inner shell
Data Source
AI summary
Electrical connectors with improved water resistance. A connector may have an outer shell and an inner shell disposed in the outer shell. The inner shell may extend beyond the outer shell in a mating direction. A portion of the inner shell that extends beyond the outer shell in the mating direction may have a surface roughness higher than portions of the inner shell such that a seal can be securely attached to the rough portion of the inner shell. The seal can be made of an adhesive shaped and cured when disposed on the rough portion. The seal can be spaced from the outer shell such that the seal can abut a mating component when the connector is pressed, in the mating direction, against the mating component, blocking ingress of environmental contaminants. The seal may also block any path between the mating ends of the inner and outer shells.