Waterproof Electrical Connector Front Sealing Inversion
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Solution Overview
Problem
Existing waterproof connectors lack a reliable sealing mechanism at the forward side, which compromises their effectiveness in preventing water ingress.
Innovation Solution
A waterproof electrical connector design featuring a terminal module with an insulative housing, metallic shield, and a sealing member positioned between the terminal module and the shield, formed by applying sealing material through a front mating port to create a sealed cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealing member is positioned at the rear side of the connector between the housing and shield, then the sealing function is achieved, but the manufacturing complexity increases and reliability is compromised
Solution Approach 1:
The patent inverts the conventional sealing location from the rear side to the front side of the connector. The sealing member is now positioned at the front end of the housing, abutting against the shield's front surface. This inversion simplifies manufacturing by allowing the sealing member to be pre-assembled with the shield as a unit, while maintaining effective sealing between the housing and shield interfaces.
Solution Approach 2:
The sealing member is pre-positioned and secured to the shield before the housing is assembled. This preliminary action ensures the sealing member is already in place and properly oriented, reducing assembly complexity and improving reliability by preventing misalignment during final assembly.
2Ease of manufacture
If a sealing member is positioned at the front side of the connector, then the manufacturing process is simplified, but the sealing effectiveness may be compromised
Solution Approach 1:
By inverting the sealing location to the front side, the patent enables the sealing member to be integrated with the shield as a pre-assembled unit. This simplifies manufacturing while maintaining sealing effectiveness through proper positioning at the front housing-shield interface.
Solution Approach 2:
The sealing member acts as an intermediary element between the housing and shield at the front interface. It provides the sealing function while allowing the housing and shield to be connected through the front mating port, simplifying the overall assembly process.
3Ease of manufacture
If the sealing member is formed by applying sealing material through the front mating port, then the manufacturing process becomes easier and more integrated, but the precision of sealing material placement must be maintained
Solution Approach 1:
The sealing material is applied through the front mating port and automatically fills the sealing cavity formed by the housing and shield interfaces. The cavity geometry guides the material placement, allowing the process to be self-correcting and reducing the need for high-precision manual placement while maintaining sealing effectiveness.
Solution Approach 2:
The housing and shield are pre-positioned to form a defined sealing cavity before the sealing material is applied. This preliminary action ensures the material is placed precisely within the correct boundaries, maintaining sealing precision while simplifying the overall manufacturing process.
Data Source
AI summary
An electrical connector includes: a terminal module including an insulative housing and a number of terminals insert molded with the housing, the housing including a base and a tongue extending forwardly from the base; a metallic shield enclosing the terminal module; and a sealing member positioned in front of the base and sealed between the terminal module and the shield. A related method of making includes: enclosing a metallic shield about a terminal module; inserting a terminal protector into a front mating port of the shield and module combination until abutting a part of the terminal module; and applying a sealing material via the front mating port into a space defined between the terminal module and the shield to form a sealing member.