Waterproof Connector Shell and Housing Design
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Solution Overview
Problem
Existing waterproof connectors face manufacturing complexity due to different thermal expansion coefficients of metal and insulating materials, leading to potential separation during high-temperature soldering and oblique fitting, which compromises waterproof integrity.
Innovation Solution
A waterproof connector design featuring a shell-side and contact-side waterproof shaped sections embedded in the housing, overlapping with a seamless waterproof member to block water entry, along with a mid-plate and insulators to manage thermal expansion and improve manufacturing ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a waterproof member is molded against the housing to cover the outer peripheral portion and board connecting sections, then waterproof properties are improved, but manufacturing complexity increases
Solution Approach 1:
The connector is divided into multiple components: a housing, a separate waterproof member, a shell, and contacts. This segmentation allows each component to be manufactured independently and then assembled, simplifying the overall manufacturing process while maintaining waterproof integrity through the dedicated waterproof member that seals the housing opening.
Solution Approach 2:
The waterproof member acts as an intermediary element between the housing and the external environment. It is inserted into the opening of the housing to provide waterproof sealing, allowing the housing to maintain its structural integrity while achieving waterproof protection without requiring the entire assembly to be molded as a single complex piece.
2Object-affected harmful factors
If metal contacts and shell are used for electromagnetic wave shielding, then electromagnetic wave shielding properties are improved, but thermal expansion differences cause separation from insulating housing during high-temperature soldering
Solution Approach 1:
The patent addresses thermal expansion differences by designing the mounting structure to accommodate dimensional changes during soldering. The housing and metal components are configured with appropriate clearances and mounting features that allow for thermal expansion without causing separation or damage during the high-temperature soldering process.
Solution Approach 2:
The connector design incorporates pre-planned compensation mechanisms for thermal expansion. The housing structure and mounting features are designed in advance to absorb and accommodate the dimensional changes that occur during soldering, preventing separation between metal components and the insulating housing before thermal stress can cause damage.
3Length of moving object
If the connector is made thinner to meet portable device requirements, then adaptability to portable devices is improved, but waterproof and shielding effectiveness may be compromised
Solution Approach 1:
The connector achieves its functions by optimizing the arrangement of components in multiple dimensions rather than simply reducing overall thickness. The waterproof member, shell, and contacts are strategically positioned and sized in different spatial dimensions to provide effective waterproofing and electromagnetic shielding while maintaining a thin profile suitable for portable devices.
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 design enhances waterproof properties and electromagnetic wave shielding while simplifying manufacturing, ensuring the connector remains effective and thin.
Implementation Method 1
a waterproof member that is seamless and is disposed around a periphery of the housing
Implementation Method 2
a shell made of metal and covering outer peripheral portions of the one or more contacts
Data Source
Figure 1A~1C
Figure 2~4
Figure 5~7
AI summary
A waterproof connector provided with: one or more contacts (12, 13); a metal shell (14) covering the outer peripheral part of the contacts (12, 13); a housing (19) comprising an insulating resin for holding the contacts (12, 13) and the shell (14); and a seamless waterproof member (20) arranged on the outer periphery of the housing (19). The shell (14) has an engaging part (15A), a shell-side substrate connection part (15H), a shell-side fixed part (15D), and a shell-side waterproof shaped part (15E) formed on the surface of the shell-side fixed part (15D). The contacts (12, 13) have contact points (12A, 13A), contact-side substrate connection parts (12C, 13C), contact-side fixed parts (12B, 13B), and contact-side waterproof shaped parts (12E, 13E) formed on the surface of the contact-side fixed parts (12B, 13B). The engaging part (15A) has a pair of flat shell outer surfaces (15C) facing in mutually opposite directions. The shell-side fixed part (15D) is arranged nearer an axis of engagement (C) with a counterpart connector than the shell outer surfaces (15C) of the engaging part (15A), as viewed from the direction of the axis of engagement (C). The shell-side waterproof shaped part (15E), the contact-side waterproof shaped parts (12E, 13E), and the waterproof member (20) are arranged at mutually overlapping positions in the direction of the axis of engagement (C).