Waterproof Electrical Connector Soldered Joint Design
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Solution Overview
Problem
Existing electrical connectors with waterproof functions are bulkier and more costly due to the inclusion of an extra insulating housing, which increases volume and expense while maintaining a good waterproof effect.
Innovation Solution
An electrical connector design featuring an insulating housing with a mating portion extending into a metallic shell cavity, where a welding seam is filled with soldering material to form a soldering segment, providing a waterproof seal without the need for an additional insulating housing, thus reducing size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating housing is added around the metallic shell to achieve waterproof function, then waterproof performance is improved, but volume and cost increase
Solution Approach 1:
The patent combines the waterproof sealing function with the existing insulating housing structure by integrating a sealing ring directly into the insulating housing. This eliminates the need for a separate insulating housing component, as the sealing ring is molded as an integral part of the housing, thereby reducing overall volume while maintaining waterproof performance.
Solution Approach 2:
The sealing ring is nested within the insulating housing structure, fitting into a groove or channel formed in the housing. This nested arrangement allows the sealing function to be incorporated without adding external volume, as the sealing element is contained within the existing housing boundaries.
2Reliability
If an insulating housing is added around the metallic shell to achieve waterproof function, then waterproof performance is improved, but cost increases
Solution Approach 1:
The sealing ring is integrated with the insulating housing through injection molding or similar manufacturing processes, creating a single-component assembly. This integration reduces the number of parts that need to be manufactured, stored, and assembled, thereby lowering overall manufacturing cost despite maintaining waterproof functionality.
Solution Approach 2:
The insulating housing is designed to serve multiple functions simultaneously: providing electrical insulation, structural support, and waterproof sealing. By making the housing multi-functional, the patent eliminates the need for separate components for each function, reducing part count and manufacturing complexity.
3Volume of moving object
If the connector is made lighter, thinner, shorter and smaller, then miniaturization is achieved, but waterproof sealing becomes more difficult
Solution Approach 1:
The patent employs a flexible sealing ring made of elastomeric material that can deform to conform to the mating connector surfaces. This flexible membrane approach allows effective sealing in compact spaces where rigid sealing structures would be too bulky, enabling waterproof performance in miniaturized connectors.
Solution Approach 2:
The sealing mechanism utilizes changes in the physical state or properties of the sealing ring material, such as elastic deformation or compression set, to create an effective seal. By changing the parameters of the sealing material (hardness, elasticity, compression resistance), the patent achieves reliable waterproof sealing in a compact configuration.
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 solution achieves a good waterproof function while minimizing the connector's volume and cost by using a soldering segment in the seam between the insulating housing and metallic shell, effectively sealing the connector without the extra housing.
Implementation Method 1
The welding seam is filled with soldering material to form a soldering segment
Data Source
AI summary
An electrical connector includes an insulating housing, a plurality of conductive terminals installed in the insulating housing and a metallic shell shielding around the insulating housing. The insulating housing has a mating portion extending forwardly thereof. The metallic shell surrounds to form a mating cavity into which the mating portion extending and a joint communicating with the mating cavity. The conductive terminals are exposed to one face of the mating portion. The joint is filled with soldering material to form a soldering segment. The electrical connector has good waterproof function with the soldering segment in the joint.