Waterproof Connector Shell Front Exposure Design
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Solution Overview
Problem
Conventional waterproof connectors face challenges in achieving effective waterproofing between the insulator and the peripheral shell, as the resin molding process often results in exposed parts and potential water entry paths, making it difficult to secure the connector in a single process without compromising the seal.
Innovation Solution
A waterproof connector design featuring a cylindrical peripheral shell with a shell front end exposure portion and through-holes, combined with a method of manufacturing where the peripheral shell is surrounded by insulating resin, ensuring the shell front end exposure portion remains exposed while the entire circumference of the peripheral shell is covered, thereby enhancing the waterproof properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulator is configured to cover the peripheral shell from its rear end through its peripheral surface to prevent water entry paths, then waterproof properties are improved, but the molding process becomes more complex and cannot be finished in a single process
Solution Approach 1:
The insulator is divided into two distinct parts: a first insulator that holds the contacts and ground plate, and a second insulator that covers the peripheral shell. This segmentation allows each insulator to be molded separately in single-process operations, avoiding the complexity of molding a single complex insulator while still achieving complete waterproof coverage when the two insulators are assembled together.
2Reliability
If the insulator is molded to cover the peripheral shell completely, then waterproof properties are improved, but the positioning accuracy during assembly becomes difficult to control
Solution Approach 1:
A positioning protrusion is introduced as an intermediary element that fits into a positioning recess on the peripheral shell. This mechanical interface serves as a precise locator between the first insulator and the peripheral shell, ensuring accurate positioning during assembly. The positioning protrusion extends from the rear end of the first insulator and engages with the recess to define the exact placement of the insulator assembly relative to the shell.
3Reliability
If resin molding is performed to cover the peripheral shell completely, then waterproof properties are improved, but exposed parts may remain after molding creating water entry paths
Solution Approach 1:
The peripheral shell is designed with a positioning recess formed in advance at a specific position on its outer surface. This pre-formed feature guides the molding process by providing a predetermined location where the insulating resin will be deposited. The resin is injected to fill the recess and extend along the peripheral shell, ensuring complete coverage without leaving exposed parts. The preliminary positioning recess acts as a template that ensures the resin reaches all necessary areas.
Data Source
AI summary
A waterproof connector to be mounted on a substrate includes one or more contacts, a peripheral shell in a cylindrical shape surrounding the one or more contacts and including a counter-connector accommodation portion that opens frontward in a fitting direction, and a housing made of insulating resin and holding the one or more contacts and the peripheral shell, the peripheral shell including a shell front end exposure portion in a cylindrical shape that is situated at a front end of the peripheral shell in the fitting direction and is exposed from the housing, and one or more through-holes that penetrate the shell front end exposure portion in a direction intersecting the fitting direction, and the housing tightly covering a whole circumference of the peripheral shell with the shell front end exposure portion being exposed.