Waterproof Connector Integral Housing Design
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Solution Overview
Problem
Existing flat cable waterproof connectors require complex attaching operations due to the need for a waterproof plug between the connector housing and the flat cable, which complicates the process and may lead to waterproof mold part breakage under load.
Innovation Solution
A waterproof connector design where the connector housing is formed integrally with the flat cable and conductive wire terminal, featuring a waterproof mold part and a holding mold part to reduce load on the waterproof mold part and ensure strong attachment without the need for a separate waterproof plug, utilizing cut-out parts or through holes for enhanced holding and a fitting lock part for secure mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a waterproof plug is attached between the connector housing and the flat cable to ensure waterproofing, then waterproofing performance is improved, but the attaching operation becomes complicated and the device complexity increases
Solution Approach 1:
The waterproof mold part and holding mold part are integrated into a single connector housing structure that is formed integrally with the flat cable. This merging eliminates the need for separate waterproof plugs and reduces the number of attachment operations while maintaining waterproofing performance through the integral formation of the housing with the cable.
Solution Approach 2:
The connector housing serves multiple functions simultaneously: it provides waterproofing through the waterproof mold part, mechanical holding through the holding mold part, and structural support by being integrally formed with the flat cable. This multi-functionality eliminates the need for separate waterproof plug components.
2Reliability
If a waterproof plug is attached between the connector housing and the flat cable to ensure waterproofing, then waterproofing performance is improved, but the attaching operation takes more time and reduces productivity
Solution Approach 1:
The waterproof mold part and holding mold part are merged into a single integral structure with the flat cable, eliminating the need for separate waterproof plug attachment operations. This integration significantly reduces assembly time and improves productivity while maintaining waterproofing performance.
Solution Approach 2:
The connector housing is pre-formed integrally with the flat cable during cable manufacturing, so that the waterproofing structure is already in place before final assembly. This preliminary action eliminates the need for time-consuming waterproof plug attachment operations during final assembly.
3Ease of operation
If the waterproof mold part is directly attached to the flat cable to simplify the attaching operation, then ease of operation is improved, but the waterproof mold part may break under load and reliability decreases
Solution Approach 1:
The connector housing is segmented into two functional parts: the waterproof mold part that provides sealing and the holding mold part that provides mechanical strength and cable holding. This segmentation allows each part to be optimized for its specific function while working together as an integral structure.
Solution Approach 2:
The connector housing utilizes composite structural design where the waterproof mold part and holding mold part are formed as an integral composite structure with the flat cable. This composite structure provides both the sealing capability of the waterproof portion and the mechanical strength of the holding portion, preventing breakage under load.
Data Source
AI summary
A waterproof connector includes a flat cable having an insulating sheath part in which a conductive wire is coated with an insulating film, a terminal connected to the conductive wire, and a connector housing fitted to a mating connector so as to connect the terminal to a mating terminal of the mating connector. The connector housing includes a mold part which is integrally formed with an end part in an extending direction of the flat cable and which covers a connecting part of the conductive wire and the terminal. The insulating sheath part has a pair of cut-out parts. The pair of cut-put parts are formed at positions which are covered with the connector housing and located at side end parts of the insulating sheath part opposed to each other in a transverse direction of the insulating sheath part.