Waterproof Electrical Connector With Insert-Molded Sealing
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Solution Overview
Problem
Existing electrical connectors lack a waterproof function due to assembly clearances between the conductive terminal and the insulating body, which compromises the reliability of electrical contact and sealing.
Innovation Solution
An electrical connector design featuring an insulative housing with a first region and recess, where a terminal module is insert-molded with terminals, and a main portion is over-molded to fill the gap between the terminal module and the housing, including a sealing portion embedded between the terminal module and the base, ensuring a waterproof seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional electrical connector structure is used with assembly clearance between conductive terminal and insulating body, then the manufacturing process is simpler, but the waterproof function is compromised
Solution Approach 1:
The insulative housing is divided into a base and a main portion, where the main portion is separately molded and then assembled to the base. This segmentation allows the main portion to specifically fill the assembly clearance between the terminal module and the base, providing waterproof sealing without complicating the overall connector structure.
Solution Approach 2:
The main portion acts as an intermediary element that fills the gap between the terminal module and the base. It includes a sealing portion that specifically addresses the waterproofing need by occupying the assembly clearance, while the base provides the structural foundation. This intermediary component resolves the contradiction by adding minimal complexity to achieve the waterproof function.
2Reliability
If assembly clearance exists between terminal module and base, then the assembly process is easier, but electrical contact stability deteriorates
Solution Approach 1:
The insulative housing is segmented into a base and a main portion, where the main portion is separately molded and then assembled to the base. This segmentation allows the main portion to specifically fill the assembly clearance between the terminal module and the base, providing waterproof sealing without complicating the overall connector structure.
Solution Approach 2:
The main portion is pre-molded with the sealing portion that is designed to fit into the assembly clearance. This preliminary preparation of the sealing structure allows for easy assembly while ensuring stable electrical contact and waterproofing, as the sealing portion automatically fills the gap when assembled.
3Reliability
If a main portion is over-molded to fill assembly clearance, then waterproof sealing is improved, but manufacturing complexity increases
Solution Approach 1:
The insulative housing is divided into a base and a main portion, where the main portion is separately molded and then assembled to the base. This segmentation allows the main portion to specifically fill the assembly clearance between the terminal module and the base, providing waterproof sealing without complicating the overall connector structure.
Solution Approach 2:
The main portion is designed with different regions having different functions: a sealing portion that fills the assembly clearance for waterproofing, and a welding portion that provides structural support. This local differentiation of quality and function allows the housing structure to achieve waterproofing with minimal added complexity.
Data Source
AI summary
An electrical connector comprising an insulative housing defining a base which includes a first region and a first recess and a plurality of terminal grooves; and a terminal module which received in said first recess, including a plurality of terminals received in said terminal grooves respectively and a substrate insert-molded upon said terminals; wherein said first recess communicates with said first region and said terminal grooves are surrounded commonly by said first region and said first recess; wherein said electrical connector includes a main portion over-molded in said first region and said first recess.