Sealed Electrical Connector Structure for Miniaturized Waterproofing

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Solution Overview

Problem

Existing electrical connectors face challenges in providing effective waterproofing and dust-proofing, especially in miniaturized designs, due to structural weaknesses and gaps that allow moisture and foreign objects to enter.

Innovation Solution

An electrical connector design incorporating a water-proof member made of liquid silicone rubber, which is injected into the gap between insulating body parts and forms a closed space with the shell, providing structural interference and sealing against moisture and dust.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the electrical connector is miniaturized to improve performance, then the size is reduced, but the structural strength and stability deteriorate

Engineering Contradiction:

Improvesize of electrical connectorVSAvoidstructural strength and stability

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The insulating body is divided into a first part and a second part separated along the mating axis, creating a modular structure that maintains structural integrity while enabling miniaturization. This segmentation allows the connector to achieve compact dimensions without compromising overall strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The water-proof member is nested within the closed space formed by the first shell and insulating body parts, with terminals passing through the insulating body. This nested arrangement maximizes space utilization, allowing the connector to be miniaturized while maintaining structural stability through layered component integration.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Ease of manufacture

If gaps are introduced between insulating body parts for assembly, then the ease of manufacture is improved, but the waterproofing performance deteriorates

Engineering Contradiction:

Improveassembly easeVSAvoidwater and dust ingress

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The water-proof member acts as an intermediary element disposed within the closed space formed by the first shell and insulating body parts. It specifically seals around the terminals that pass through the insulating body, preventing water and dust from entering through the gap between the first and second parts while maintaining assembly feasibility.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The water-proof member is made of liquid silicone rubber, a flexible material that can conform to the gap geometry between insulating body parts and terminals. This flexible sealing film effectively blocks water and dust penetration while allowing for manufacturing tolerances and assembly variations.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If terminals are exposed from the insulating body for connection, then the electrical connectivity is improved, but the protection against foreign objects deteriorates

Engineering Contradiction:

Improveelectrical connectivityVSAvoidforeign object ingress

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The water-proof member serves as an intermediary sealing element that specifically addresses the exposure points of terminals. It conforms to and seals around the terminal portions that extend through the insulating body, maintaining electrical connectivity while preventing water, dust, and other foreign objects from entering through terminal openings.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 ensures a comprehensive waterproof and dust-proof mechanism, even with gaps between components, by forming a sealed structure that prevents the ingress of foreign objects and moisture, enhancing the connector's structural strength and stability.

Implementation Method 1

the water-proof member is liquid silicone rubber injection molding

Methodology Applied

Scientific EffectLiquid silicone rubber injection molding:

Implementation Method 2

structural interference is generated during assembly of the water-proof member and the first shell

Methodology Applied

Scientific EffectStructural interference:

Data Source

PatentUS12592512B2Electrical connector with water-proof member

Publication Date: 2026.03.31 ADVANCED CONNECTEK INC

AI summary

Disclosed is an electrical connector configured to be mated with another electrical connector along a mating axis. The electrical connector includes an insulating body, a plurality of terminals, a first shell, and a water-proof member. The insulating body includes a first part and a second part separated from each other along the mating axis to form a gap between the first part and the second part along the mating axis. The plurality of terminals are disposed through the insulating body. The first shell is sleeved on the insulating body. The first shell, the first part, and the second part form a closed space at the gap. The water-proof member is disposed at the insulating body and located in the closed space.