Waterproof Power Plug Housing With Glue-Sealed Wire Entry
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Solution Overview
Problem
Existing power plug devices lack a waterproof or dustproof structure, leading to moisture and particle penetration, which causes electrode corrosion, malfunctions, and potential safety hazards such as fire or current leakage.
Innovation Solution
A power plug device design featuring a double-layered waterproof structure with an upper-housing body, sealed bottom, and interlocking convex and concave portions, along with a conducting wire assembly and circuit board, where the receptive space is filled with glue to secure core wires and enhance sealing, and the housings are ultrasonically welded to form a sealed assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a power module with PCB is used for electric power connection, then the electrical connection function is achieved, but the device lacks waterproof and dustproof protection allowing moisture and particles to penetrate and accumulate on electrodes
Solution Approach 1:
The housing is divided into an upper housing and a lower housing that can be assembled separately and then connected to form a complete sealed enclosure. This segmentation allows for easier manufacturing and assembly while maintaining the waterproof protection for the internal PCB and electrical components
Solution Approach 2:
A waterproof seal ring is introduced as an intermediary component between the upper and lower housings to create the waterproof connection. The seal ring fills the gap between housing parts and prevents moisture and dust from penetrating into the internal electrical components
2Ease of manufacture
If the housing structure is designed with multiple assembly parts for ease of manufacturing, then the manufacturing process is simplified, but the waterproof sealing between parts becomes more difficult to achieve
Solution Approach 1:
A flexible waterproof seal ring is used to create the sealing barrier between housing parts. The elastic material of the seal ring allows it to deform and adapt to the housing surfaces, ensuring a reliable waterproof seal while maintaining ease of assembly through simple snap-fit or screw connections
3Ease of operation
If conventional housing connection methods are used, then the assembly process is simple, but the connection lacks waterproof structure allowing moisture ingress
Solution Approach 1:
The waterproof seal ring serves as an intermediary element that is integrated into the housing connection structure. It maintains the simplicity of assembly by using standard mechanical fastening methods while simultaneously providing the waterproof barrier function that prevents moisture ingress
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 effectively prevents moisture and dust ingress, reducing the risk of electrode corrosion and ensuring the longevity and safety of electrical equipment by maintaining a reliable electrical connection.
Implementation Method 1
a waterproof seal installed in the connection between the upper-housing and the lower-housing, wherein the waterproof seal prevents water from penetrating into an internal space of the power supply plug
Implementation Method 2
the receptive space is filled with glue to secure the core wires
Implementation Method 3
the housings are ultrasonically welded to form a sealed assembly
Data Source
AI summary
A power plug device includes a first housing, a circuit board, a wire assembly and a second housing. The first housing includes an upper-housing body, a through hole and an inner cover. An accommodating portion is arranged in the upper-housing body, the through hole is formed on one side of the upper-housing body, the inner cover is installed in the accommodating portion, a receptive space is arranged in the inner cover, and the through hole interconnects with the receptive space. The wire assembly includes core wires, which passes through the through hole and the receptive space, so that the core wires are accommodated in the accommodating portion, and the receptive space is suitable for accommodating glue to secure the core wires and provides waterproof effect. In addition, dual-layered waterproof structure is used to make the first and second housing joining together having stronger waterproof effect.