Waterproof Electronics Modules with Counterbore Sealing
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Solution Overview
Problem
Manufacturing waterproof electronic toys is costly due to the need for closely matched surfaces and contours in housing components to ensure a reliable seal, which is challenging for electronic water toys that require protection from water to prevent short circuits.
Innovation Solution
The design employs waterproof electronics modules with insulated wires passing through compartments, each with a through hole and counterbore sealed with a sealant, and a non-waterproof outer housing that mechanically interconnects these modules, allowing for leak testing and plugging of test ports to maintain waterproof integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gasket is placed between upper and lower housing components with compression force to seal the interface, then waterproofing is achieved, but manufacturing cost increases due to the need for closely matched surfaces and contours
Solution Approach 1:
The patent divides the housing into multiple separable components (first housing component, second housing component, third housing component) that can be manufactured independently and then assembled. This segmentation allows each component to be produced using standard manufacturing processes without requiring expensive closely-matched surfaces, while the gasket seals the interfaces between these standardized components.
2Reliability
If the outer housing is made fully waterproof, then water protection is comprehensive, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent applies waterproofing selectively at critical interfaces where housing components meet (using gaskets at the seams between first/second and second/third housing components) rather than making the entire outer housing uniformly waterproof. This localized approach to waterproofing reduces manufacturing complexity while providing adequate protection at the points where water penetration is most likely.
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
This approach reduces manufacturing costs by distributing waterproof components within the toy, ensuring effective water protection without requiring a fully waterproof outer housing, while maintaining electrical connectivity and functionality.
Implementation Method 1
a sealant that at least partially fills the corresponding counterbore of the through hole thereby providing a waterproof seal between the insulated wire passing through the hole and the waterproof compartment
Data Source
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AI summary
The present disclosure is directed to an electronic water toy (100) and techniques to protect electrical components of the toy from water. The toy may include a plurality of waterproof electronics modules (212,230,232), a non waterproof outer housing (110), and a plurality of insulated wires (250). Each waterproof electronics module may include an electrical component, and a waterproof compartment (112,114) to house the electrical component (220,222,224) and to protect the electrical component from water. The non waterproof outer housing (110) may physically interconnect the plurality of waterproof electronics modules. The waterproof compartment (112,114) may include counterbore through holes to permit wires (250) through the waterproof compartment and a counterbore leak test port to permit pressure testing of the waterproof compartment (112,114).