Waterproof Electrical Connector Shielding Shell Segmentation
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Solution Overview
Problem
Existing electrical connectors with waterproof properties have complex manufacturing processes due to their intricate structures, making them difficult to produce efficiently.
Innovation Solution
An electrical connector design featuring a terminal module with an insulative housing and conductive terminals, surrounded by a shielding shell with a metallic shell and a waterproof shell, where a sealing member covers an opening slot between the metallic and waterproof shells, and a retaining member with mounting legs is used to simplify the molding die and manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex metallic shell structure with four mounting legs is used to achieve waterproof property, then waterproof performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the shielding shell into separate components: a metallic shell and a waterproof shell, which are assembled together rather than formed as a single complex piece. This segmentation allows each component to have a simpler structure while achieving the overall waterproof function through their combination and the sealing member between them.
Solution Approach 2:
The patent introduces a sealing member as an intermediary element between the metallic shell and the waterproof shell. This sealing member specifically addresses the waterproof requirement at the interface between components, allowing the shells themselves to have simpler structures without compromising waterproof performance.
2Reliability
If a complex metallic shell structure is used to achieve waterproof property, then waterproof performance is improved, but manufacturing process complexity increases
Solution Approach 1:
By segmenting the shielding shell into separate metallic shell and waterproof shell components, each piece can be manufactured using simpler molding dies and processes. The metallic shell can be formed by conventional metal forming techniques, while the waterproof shell can be molded separately, avoiding the need for a single complex mold that would require intricate design and manufacturing.
Solution Approach 2:
The patent combines multiple simpler manufacturing processes for separate components into an final assembled product. Rather than requiring a single complex molding operation, the simpler processes for making the metallic shell, waterproof shell, and sealing member are combined through assembly, reducing overall manufacturing process complexity.
3Reliability
If a complex metallic shell structure is used to achieve waterproof property, then waterproof performance is improved, but production efficiency decreases
Solution Approach 1:
The segmented structure allows parallel manufacturing of the metallic shell, waterproof shell, and sealing member components. Each component can be produced independently and simultaneously in different workstations or even different facilities, then assembled together. This parallel production approach significantly improves productivity compared to manufacturing a single complex integrated shell.
Solution Approach 2:
The sealing member can be pre-installed onto the metallic shell or prepared in advance before the final assembly with the waterproof shell. This preliminary action ensures waterproof integrity is built into the assembly process itself, allowing for efficient production line integration without requiring complex post-assembly waterproofing operations.
Data Source
AI summary
An electrical connector includes a terminal module and a shielding shell surrounding the terminal module. The terminal module has an insulative housing and a plurality of conductive terminals retained in the insulative housing. The shielding shell has a metallic shell and a waterproof shell insert molded on an outer side of the metallic shell. The metallic shell surrounds the insulative housing to form a mating cavity opening forwardly. The shielding shell has a sealing member disposed between the metallic shell and the waterproof shell and a retaining member disposed at a rear side of the waterproof shell. The retaining member is separate from the sealing member. The metallic shell defines an opening slot going therethrough. The sealing member covers the opening slot. The retaining member defines a mounting leg.