Ultrasonic Welded Shell Joint for Waterproof Electronic Modules
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Solution Overview
Problem
Existing electronic modules lack a sufficient waterproof joint mechanism, compromising their structural strength, electrical characteristics, and appearance, while also failing to prevent fluid ingress.
Innovation Solution
The electronic module employs a first and second shell with complementary joint units, including projection and indentation portions, and a bump, joined by ultrasonic welding to form bonding layers, which seals the module from fluids and enhances structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional joint mechanisms are used for shells, then the shells can be assembled, but the joint is insufficient to stop fluid flowing into the housing and compromises structural strength
Solution Approach 1:
The joint unit is divided into multiple functional segments: a first joint unit on the first shell and a second joint unit on the second shell. These segmented joint units feature complementary protrusions and recessions that interlock to provide both waterproof sealing and structural strength, resolving the contradiction between assembly ease and joint sufficiency.
Solution Approach 2:
The joint units employ a nested structure where protrusions from one shell fit into recessions of the other shell, creating an interlocking configuration. This nesting mechanism ensures fluid tightness while maintaining structural integrity, as the interlocked geometry prevents fluid ingress and distributes mechanical loads effectively.
2Ease of manufacture
If conventional joint mechanisms are used for shells, then the shells can be assembled, but the joint adversely affects appearance and electrical characteristics
Solution Approach 1:
The joint unit merges multiple functions into a single integrated structure: sealing, mechanical joining, and electrical isolation. By combining these functions into one unified joint mechanism with complementary protrusions and recessions, the design simplifies assembly while avoiding the complexity of multiple separate components, thus resolving the contradiction between ease of manufacture and device complexity.
3Reliability
If shells are joined without proper joint mechanism, then assembly is simple, but fluid can flow into the housing
Solution Approach 1:
The joint units are designed with complementary protrusions and recessions that automatically align and interlock during assembly. This self-aligning mechanism ensures proper positioning and creates a fluid-tight seal without requiring complex alignment procedures or additional fastening operations, thus achieving waterproof performance while maintaining ease of operation.
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 solution effectively prevents fluid ingress, maintains structural strength, and addresses electro-static discharge issues, enabling the module to pass drop and falling ball tests while ensuring a watertight seal.
Implementation Method 1
joined by ultrasonic welding to form bonding layers
Data Source
AI summary
An electronic module includes first and second shells respectively having first and second edge surfaces with respective first and second joint units jointed together by ultrasonic welding. The first joint unit has first and second projection portions on the first edge surface, a first indentation portion between the first and second projection portions, and a bump on the second projection portion. The second joint unit complementarily engages the first joint unit. First and second bonding layers are respectively formed between the first indentation portion and the second joint unit and between the second projection portion and the second joint unit. Waterproof cable assemblies are mounted to the shells.