Waterproof Connector Sealing for Exposed Core Wire Insertion
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Solution Overview
Problem
Conventional connectors are non-waterproof and attempting to make them waterproof results in damage to the sealing portion due to the core wire exposed at the tip of the wire when inserted into the wire insertion hole.
Innovation Solution
A connector design with a core wire covered by an insulation coating, featuring a sheath portion and a body portion that are separate and slidable, along with an inner and outer sealing system to protect the sealing portion from damage and ensure waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a one-piece rubber plug is mounted into the rear end part of the inner housing to waterproof the wire, then waterproofing is improved, but the core wire may damage the sealing portion of the rubber plug during insertion
Solution Approach 1:
The patent introduces a guide portion as an intermediary structure that mediates between the core wire and the sealing portion. The guide portion is positioned to contact the core wire before the sealing portion, guiding the wire into the correct position and preventing the core wire from directly damaging the sealing portion during insertion. This resolves the contradiction by providing a protective intermediary element.
Solution Approach 2:
The guide portion serves as a beforehand cushioning structure that prepares for potential damage by intercepting the core wire first. By positioning the guide portion to contact the core wire before the sealing portion, the design anticipates and prevents the harmful interaction between the sharp core wire and the sealing portion, thereby protecting the waterproofing function.
2Reliability
If the insulation coating is stripped to expose the core wire for connection, then electrical connection is improved, but the exposed core wire tip may damage the sealing portion
Solution Approach 1:
The guide portion acts as an intermediary that separates the function of electrical connection from the function of sealing. It allows the exposed core wire tip to be positioned correctly for electrical connection while preventing direct contact with the sealing portion, thus resolving the contradiction between achieving good electrical connection and preventing damage to the sealing portion.
Solution Approach 2:
The patent segments the functions by introducing a separate guide portion structure that is distinct from both the insulation coating and the sealing portion. This segmentation allows the core wire to fulfill its electrical connection function while the guide portion protects the sealing portion, enabling both functions to coexist without interference.
3Reliability
If multiple separate sealing components are used to waterproof different parts, then waterproofing reliability is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The patent merges the sealing function into a single integrated rubber plug component that provides comprehensive waterproofing. Rather than using multiple separate sealing components, the one-piece rubber plug combines the sealing portion and guide portion into one unified structure, reducing device complexity and manufacturing time while maintaining waterproofing reliability through the integrated design.
Data Source
AI summary
A connector includes a wire including a core wire and an insulation coating covering an outer periphery of the core wire, a terminal to be connected to the core wire, an inner housing including a terminal accommodating portion for accommodating the terminal inside, a rear holder to be attached to a rear part of the inner housing and a collective sealing portion to be mounted into the rear holder. The rear holder includes a wire insertion hole, through which the wire is inserted. The collective sealing portion includes an inner sealing portion for sealing the wire inserted through the wire insertion hole. The insulation coating of the wire includes a sheath portion and a body portion separate from each other. The sheath portion is disposed forward of the body portion and slidable with respect to the core wire.