Seamless Waterproof Connector Shell for Compact Durable Layouts
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Solution Overview
Problem
Conventional waterproof connectors are bulky and prone to fractures due to seams, limiting size reduction in electronic devices and compromising durability.
Innovation Solution
A seamless, tubular metal shell with a resin support and sealing member around its periphery, eliminating the need for an external resin housing, which reduces the connector's size, enhances strength, and ensures waterproof performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the shell is attached to the resin housing by fitting from outside, then the waterproof function is achieved, but the connector length increases and area is increased
Solution Approach 1:
The shell and resin housing are merged into a single integrated component formed by insert molding. The contact terminals are molded directly into the resin housing, eliminating the need for separate assembly steps and reducing the overall connector length while maintaining waterproof integrity.
Solution Approach 2:
The contact terminals are nested within the resin housing during insert molding, and the shell is then fitted over this nested structure. This nested arrangement allows compact integration of components, reducing the connector's external dimensions while preserving the waterproof sealing function.
2Ease of manufacture
If the shell is formed by press molding and connecting end portions, then the shell structure is created, but seams are produced that reduce strength and durability
Solution Approach 1:
The shell is formed as a seamless tubular structure using draw molding, which creates a continuous form without seams or joints. This seamless construction eliminates weak points where fractures could initiate, dramatically improving the shell's strength and durability while maintaining manufacturability.
3Shape
If the shell is formed by connecting plate-like member ends, then the shell shape is achieved, but seams extend throughout the insertion direction reducing reliability
Solution Approach 1:
The shell is formed as a seamless tubular structure using draw molding, which creates a continuous form without seams or joints. This seamless construction eliminates weak points where fractures could initiate, dramatically improving the shell's strength and durability while maintaining manufacturability.
Data Source
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AI summary
A waterproof connector provided herein is capable of reducing an area taken up by the connector while ensuring waterproof performance, achieving layout design of electronic equipment more freely, and contributing to size reduction of the electronic equipment. This waterproof connector is also capable of increasing the strength and durability of a shell dramatically. A waterproof connector (1) includes: a shell (2) of a seamless and substantially tubular shape; a resin support (3) accommodated in a wall pattern in the shell (2); a contact terminal (4) attached to the support (3) for example by insert molding and supported by the support (3); and a sealing member (5) provided around an outer periphery of the shell (2). Preferably, the shell (2) is provided with a non-through recess (26) formed so as to bulge outward. The non-through recess (26) allows engagement of a hook of a plug.