Waterproof Control Unit Sealing Structure
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Solution Overview
Problem
Existing waterproof control units face challenges with long connector housing dimensions, increased electric resistance, and manufacturing complexities due to the need for two types of convexoconcave sealing surfaces, which complicate downsizing and increase the weight and cost of the device.
Innovation Solution
A waterproof control unit design featuring a casing with a base and cover, utilizing slope portions and flat portions to create narrow-gap sealing spaces, along with gap regulating members and plane movement regulating members to maintain a predetermined gap dimension, reducing the need for complex die structures and minimizing connector housing length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two types of convexoconcave sealing surfaces are provided in the connector housing to ensure waterproof sealing, then sealing reliability is improved, but the connector housing body dimension becomes long and device complexity increases
Solution Approach 1:
The patent merges the convexoconcave sealing surfaces into a single integrated structure on the connector housing, eliminating the need for two separate sets of sealing surfaces. This unified design maintains waterproof sealing reliability while reducing the body dimension and structural complexity of the connector housing.
Solution Approach 2:
The single convexoconcave sealing surface structure serves multiple functions: it provides waterproof sealing between the connector housing and both the cover and base, and simultaneously regulates the gap dimensions. This multi-functional design reduces the need for additional components and simplifies the overall structure.
2Ease of manufacture
If the connector housing body dimension is reduced to simplify the die structure, then ease of manufacture is improved, but the sealing path length decreases and sealing reliability may be compromised
Solution Approach 1:
The patent optimizes the parameters of the convexoconcave sealing surface, including the depth of the concave portion and the height of the convex portion, to achieve the required sealing path length within a reduced body dimension. By carefully adjusting these geometric parameters, the design maintains sealing reliability while simplifying the die structure and reducing manufacturing complexity.
3Reliability
If the convex thread wall surface abuts on the concave thread wall surface due to assembly dimension error, then the film thickness of waterproof sealing material becomes zero, but the waterproof sealing material is still filled in the gap between other wall surfaces
Solution Approach 1:
The convexoconcave sealing surface design inherently compensates for assembly dimension errors. The interlocking convex and concave threads create a mechanical interference fit that maintains sealing pressure even when dimensional tolerances are not perfectly met. This beforehand cushioning effect ensures that the waterproof sealing material is reliably filled in the gap between wall surfaces regardless of minor assembly variations.
Data Source
AI summary
In a waterproof control unit (100A) in which a part of a connector housing (330A) mounted on a circuit board (300A) is exposed and the circuit board (300A) is hermetically housed in a casing including a base (200A) and a cover (400A), in a gap between the cover and the connector housing, a waterproof sealing material (501) is applied to a first sealing gap defined by outer-step flat portions (401a,301a), slope portions (401b,301b), and inner-step flat portions (401c,301c), and in a gap between the base (200A) and the connector housing (330A) or between the base (200A) and the cover (400A), a waterproof sealing material (502,503) is applied to a second or third sealing gap defined by convexoconcave sealing surfaces having a convex thread loosely fitted into a concave thread.