Waterproof Connector Seamless Metal Shell Segmentation
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Solution Overview
Problem
Existing waterproof connectors face challenges in achieving efficient manufacturing while maintaining waterproof performance, reducing connector length, and enhancing shell strength without the need for a resin housing, which increases complexity and cost.
Innovation Solution
A waterproof connector design featuring a seamless first shell and a seamless or seam-ed second shell, with an outer and inner sealing member to prevent water ingress, allowing for reduced length, increased internal space, and simplified manufacturing, eliminating the need for a resin housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a seamless shell is formed by high-degree processing, then waterproof performance is secured and shell strength is improved, but manufacturing efficiency decreases and manufacturing cost increases
Solution Approach 1:
The shell is divided into multiple segments (first shell and second shell) that can be manufactured separately using standard pressing processes, then assembled together. This segmentation allows each part to be produced efficiently without requiring complex seamless forming operations, while the assembled structure still achieves waterproof performance through proper joining and sealing.
Solution Approach 2:
The first shell and second shell are nested together to form the complete shell structure. The first shell is inserted into the second shell, creating a layered configuration that maintains structural integrity and waterproof performance while allowing each component to be manufactured independently using simpler, more efficient processes.
2Strength
If a seamless shell is formed by high-degree processing, then shell strength is improved, but manufacturing cost increases
Solution Approach 1:
The shell structure is segmented into multiple pressable parts that can be manufactured using conventional, cost-effective pressing techniques. By avoiding the need for expensive seamless forming operations, the manufacturing cost is reduced while the overall shell strength is maintained through proper design of the segmented structure and its assembly.
Solution Approach 2:
Multiple separately manufactured shell parts are combined through assembly to form the complete shell structure. This merging of independently produced components achieves the required structural strength without incurring the high costs associated with forming a single seamless shell, thereby improving ease of manufacture and reducing manufacturing cost.
3Reliability
If a resin housing is added to prevent water entry through seam, then waterproof performance is improved, but device complexity increases
Solution Approach 1:
The shell is designed as segmented metal parts that can be precisely assembled to create water-tight joints without requiring an additional resin housing. The segmentation allows for controlled assembly interfaces that inherently provide waterproofing through proper fitting and sealing, eliminating the need for extra protective layers and reducing structural complexity.
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
A waterproof connector (1) includes: a first shell (2) having an approximately tubular form, formed of metal and disposed on a plug insertion side; a second shell (3) having an approximately tubular form, formed of metal and engaged with a rear portion of the first shell (2); an outer sealing member (4) provided on an outer circumference of the first shell (2) so as to abut on a front surface portion (31) of the second shell (3) positioned on an outer side of the first shell (2); a supporting portion (5) accommodated in a wall form in a rear portion of an engagement assembly of the first shell (2) and the second shell (3) in a state in which water does not enter toward a rear side from a space between the engagement assembly and the supporting portion; and contact terminals (6) supported by the supporting portion (5). At least one of the first shell (2) and the second shell (3) is seamless. In this way, it is possible to provide a waterproof connector having a low manufacturing cost and excellent manufacturing efficiency, capable of securing a waterproof performance, decreasing the length of the connector, improving the strength of the shell, and eliminating the need of a resin housing for preventing entrance of water.