Reflow-Solderable Waterproof Connector for Camera Modules
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Solution Overview
Problem
Existing connector configurations for on-vehicle modules, such as those using the FAKRA and USCAR standards, face challenges with waterproofness when using reflow soldering, as the heat can damage seal members like O-rings, leading to loss of waterproof functionality and increased connector size due to the need for screw holes and contact stroke accommodation.
Innovation Solution
A connector design featuring a cylindrical external conductor with heat-resistant first and second seal members, made from materials like silicone rubber, which can withstand reflow soldering temperatures up to 260°C, allowing for surface mounting on a substrate while maintaining waterproofness without the need for a relay connector, thus eliminating the requirement for screw holes and reducing overall size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional connector with O-ring seal members is used and mounted by reflow soldering, then the connector can be surface-mounted on the substrate, but the seal members are damaged by the heat and lose waterproofness
Solution Approach 1:
The seal members are changed from conventional materials to heat-resistant materials (silicone rubber or fluororubber) that can withstand reflow soldering temperatures of 260°C or higher, enabling surface mounting while maintaining waterproofness
Solution Approach 2:
The connector uses composite construction with heat-resistant seal members (silicone rubber or fluororubber) combined with metal conductors and insulators, creating a structure that survives reflow soldering while maintaining sealing function
2Strength
If screw holes are provided in the rear case for fastening the relay connector, then the connector can be securely mounted, but the overall size increases and internal space is reduced
Solution Approach 1:
The relay connector is completely removed from the structure, eliminating the need for screw holes and associated mounting hardware, thereby reducing overall size and increasing internal space while maintaining secure connection through direct substrate mounting
Solution Approach 2:
The connector base directly mounts to the substrate without requiring a separate relay connector, combining multiple functions into a single integrated structure that reduces component count and space requirements
3Reliability
If the position of the substrate is pushed downward to ensure contact stroke, then the connector can function properly, but the overall size increases
Solution Approach 1:
The connector uses elastic deformable seal members that can dynamically adjust to ensure proper contact stroke without requiring fixed downward positioning, allowing the substrate to remain in its original position while maintaining reliable electrical contact
4Ease of manufacture
If a through hole is formed in the substrate to solder the substrate connector, then the connector can be mounted, but the thickness dimension and weight of the substrate increase
Solution Approach 1:
The through-hole structure is completely eliminated, replacing it with surface mounting of the connector on the substrate, thereby reducing substrate thickness and weight while maintaining secure electrical connection through surface soldering
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 heat-resistant seal members enable reliable waterproofing during reflow soldering, reducing the connector's size and expanding internal space within the camera module by eliminating the need for relay connectors and screw holes, while ensuring the connector's functionality is preserved.
Implementation Method 1
the first seal member and the second seal member have heat resistance durable against a temperature of reflow soldering performed when the connector is mounted on the substrate
Data Source
AI summary
A connector is provided that can be mounted on a surface of a substrate by reflow soldering while ensuring waterproofness due to a seal member. A cylindrical external terminal extends in an axis direction with an outer bush in close contact with an outer circumferential face of the external terminal. An inner bush is in close contact with an inner circumferential face of the external terminal. A contact pin is inserted in the inner bush along the axis direction inside the external terminal, and the outer bush and the inner bush have heat resistance durable against a temperature of reflow soldering performed when the connector is mounted on the substrate. A connector assembly, a camera module and an assembly method are also provided.