Waterproof Connector Drainage Path Design
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Solution Overview
Problem
Existing waterproof connectors for vehicles face challenges in effectively preventing water ingress through wire insertion holes, particularly when inclined, leading to water pooling between the holder and rubber plug, which can compromise the sealing efficiency.
Innovation Solution
The design incorporates a drainage path with a water inlet and outlet in the connector housing, where the water inlet is positioned below the holder's facing surface and the water outlet is closer to the back wall, allowing water to be guided and discharged outside, along with guide ribs and grooves to ensure proper alignment and drainage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wire insertion holes are provided in the holder for drawing out wires, then wire installation is enabled, but water can enter through the holes and pool in the clearance between the holder and rubber plug
Solution Approach 1:
The drainage path extracts the harmful water that enters through the wire insertion holes by providing a dedicated discharge route. The water inlet positioned below the holder's facing surface captures pooled water, and the drainage path guides it to the water outlet that opens to the exterior, effectively removing the harmful accumulation.
Solution Approach 2:
The drainage path acts as an intermediary structure between the interior clearance space and the exterior environment. It mediates the water flow by providing a controlled passage from the water inlet through the lower wall to the water outlet, preventing water from remaining in the harmful pooled state.
2Adaptability or versatility
If the connector is inclined with the back wall lower than the opening, then water may flow to the facing surface through wire insertion holes, but this configuration allows drainage path to effectively discharge water
Solution Approach 1:
The drainage path design creates an equipotential drainage system where the water inlet position and drainage path geometry ensure that water can flow to the outlet regardless of the connector's inclination angle. The path is configured to maintain effective water discharge capability across different gravitational orientations.
Solution Approach 2:
The drainage path parameters (inlet position, path geometry, outlet position) are optimized to change the water flow behavior adaptively. By positioning the water inlet below the facing surface and the outlet closer to the back wall, the system adjusts to different inclination scenarios and maintains drainage effectiveness.
3Ease of operation
If water inlet is positioned below the holder's facing surface, then water can be guided to drainage hole, but the inlet size must be sufficient for smooth water flow
Solution Approach 1:
The water inlet is preliminarily positioned below the holder's facing surface during design and manufacturing, anticipating the water flow path. This pre-positioning ensures that water naturally drains toward the inlet without requiring complex active control mechanisms, simplifying both operation and manufacturing.
Solution Approach 2:
The drainage path geometry is designed with standardized proportions and shapes that are replicated from proven effective designs. This copying approach ensures adequate flow capacity while simplifying manufacturing precision requirements, as the geometry is optimized for self-similar scaling.
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 configuration ensures quick discharge of water from the connector, maintaining sealing efficiency even when the connector is inclined, reducing the likelihood of water pooling and ingress.
Implementation Method 1
water that enters through the wire insertion hole and reaches the facing surface can be guided smoothly to the drainage hole and discharged to outside
Data Source
AI summary
A male connector (1) includes terminal-equipped wires (10), a male housing (20) having a male terminal holding portion (21) and a rubber plug accommodating portion (32). A one-piece rubber plug (50) and a holder (60) are accommodated in the rubber plug accommodating portion (31). The rubber plug accommodating portion (31) includes a surrounding wall (33) that surrounds the rubber plug (50) and the holder (60). The surrounding wall (33) includes a lower wall (33B) below the rubber plug (50) and the holder (60). Drainage holes (36) penetrate through the first lower wall (33B), and each has a water inlet (36A) open on an inner side of the lower wall (33B) and a water outlet (36B) open on an outer side. The holder (60) has a contact surface (61A) configured to contact the rubber plug (50), and the water inlets (36A) are arranged right below the contact surface (61A).


