Waterproof Electrical Connector with Sealed Terminal Module
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Solution Overview
Problem
Existing audio jack connectors face difficulties in assembly due to complex structures and lack a waterproof function, which is inadequate for modern electronic devices.
Innovation Solution
An electrical connector design featuring a mating cavity with a main body, terminal module, and sealing member, where the terminal module is received in the main body, and a sealing material, such as epoxy resin, is used to fill the gaps between the components, including an O-ring member made of rubber to create a waterproof seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex structure is used for the audio jack connector, then the assembly difficulty increases, but the waterproof function is not achieved
Solution Approach 1:
The connector is divided into distinct functional modules: a waterproof shell containing the sealing mechanism, and a terminal module containing the conductive terminals. This segmentation allows each module to be optimized independently - the shell focuses on waterproofing while the terminal module handles electrical connections, resolving the contradiction between achieving waterproof function and maintaining structural simplicity.
Solution Approach 2:
The terminal module is nested within the waterproof shell, with the conductive terminals housed inside the sealed cavity. This nested arrangement allows the waterproof shell to protect the entire terminal assembly without requiring complex external sealing structures, achieving waterproof function through a simple containment approach.
2Reliability
If the conductive terminals are difficult to assemble into the insulating housing, then the manufacturing complexity increases, but the waterproof function remains unachieved
Solution Approach 1:
By separating the assembly process into two independent steps - first assembling the terminal module as a complete unit, then installing it as a single component into the waterproof shell - the invention dramatically simplifies manufacturing. The terminal module can be pre-assembled and tested independently, and the waterproof shell provides a simple receiving cavity, eliminating the need for complex in-situ assembly operations.
Solution Approach 2:
The terminal module is completely assembled beforehand, including all conductive terminals and their connections to the insulating housing, before being installed into the waterproof shell. This preliminary assembly allows for simplified final installation while ensuring all electrical connections are properly established, improving both manufacturing ease and waterproof reliability.
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 provides an electrical connector with a stable and convenient assembly process for conductive terminals and an effective waterproof function, preventing liquid ingress into electronic devices.
Implementation Method 1
The sealing member is filled in a gap between the terminal module and main body to seal the gap
Implementation Method 2
an O-ring member made of rubber to create a waterproof seal
Data Source
AI summary
An electrical connector has a mating cavity opening forwardly. The electrical connector has a main body, a terminal module and a sealing member. The terminal module has an insulator and a plurality of conductive terminals received therein. The conductive terminals have contacting portions exposed into the mating cavity and connecting legs. The terminal module is received in the main body. The sealing member is filled in a gap between the terminal module and main body to seal the gap.