Electronic module with an improved shell and method for making the same

An electronic module includes first and second shells respectively having first and second edge surfaces with respective first and second joint units jointed together by ultrasonic welding. The first joint unit has first and second projection portions on the first edge surface, a first indentation portion between the first and second projection portions, and a bump on the second projection portion. The second joint unit complementarily engages the first joint unit. First and second bonding layers are respectively formed between the first indentation portion and the second joint unit and between the second projection portion and the second joint unit. Waterproof cable assemblies are mounted to the shells.

FIELD

The disclosure relates to an electronic module, and more particularly to an electronic module with an improved shell, and a method for making the electronic module.

BACKGROUND

To meet different power specifications of numerous electronic products, various electronic modules, such as power adapters, power transformers and power connectors, have been provided in the art. Such an electronic module has a housing formed by upper and lower shells to isolate interior electronic elements from exterior dust or vapors. However, such shells do not have a joint sufficient to stop fluid flowing into the housing. In other word, such an electronic module is not waterproof. Further, the joint mechanisms used for the shells adversely affects not only appearance of the electronic module, but also the entire structural strength and electrical characteristics thereof. Therefore, it is important to provide an electronic module with shells having a proper joint mechanism that is waterproof.

SUMMARY

An object of the present disclosure is to provide an electronic module.

According to one aspect of the present disclosure, an electronic module includes a first shell and a second shell.

The first shell includes a first base wall, a first surrounding wall connected around the first base wall, a first joint unit, and a bump. The first surrounding wall has a first outer surface, a first inner surface opposite to the first outer surface, and a first edge surface connecting between the first outer and inner surfaces oppositely of the first base wall. The first joint unit is disposed on the first edge surface. The first joint unit has a first projection portion that projects from the first edge surface and that adjoins the first outer surface, a second projection portion that projects from the first edge surface and that adjoins the first inner surface, and a first indentation portion disposed between the first and second projection portions. The bump protrudes from the second projection portion oppositely of the first edge surface.

The second shell covers the first shell and includes a second base wall, a second surrounding wall connected around the second base wall, and a second joint unit. The second surrounding wall has a second outer surface, a second inner surface opposite to the second outer surface, and a second edge surface connecting between the second outer and inner surfaces oppositely of the second base wall. The second joint unit is disposed on the second edge surface. The second joint unit has a first shoulder portion aligned with the first projection portion, a third projection portion aligned with the first indentation portion, and a second shoulder portion aligned with the second projection portion.

The first and second joint units are joined with each other in such a manner that the first project ion portion, the first indentation portion and the second projection portion respectively and complementarily match the first shoulder portion, the third projection portion and the second shoulder portion.

Another object of the present disclosure is to provide a first shell for coupling with a second shell.

According to another aspect of the present disclosure, a first shell for coupling a second shell includes a first base wall, a first surrounding wall, a first joint unit and a bump.

The first surrounding wall is connected around the first base wall. The first surrounding wall has a first outer surface, a first inner surface opposite to the first outer surface, and a first edge surface connecting between the first outer and inner surfaces.

The first joint unit is disposed on the first edge surface for joining with the second shell. The first joint unit has a first projection portion that projects from the first edge surface and that adjoins the first outer surface, a second projection portion that projects from the first edge surface and that adjoins the first inner surface, and a first indentation portion disposed between the first and second projection portions.

The bump protrudes from the second projection portion oppositely of the first edge surface.

Still another object of the present disclosure is to provide a method of producing an electronic module.

According to still another aspect of the present disclosure, a method of producing an electronic module includes:

producing a first shell, the first shell including a first base wall, a first surrounding wall connected around the first base wall, a first joint unit, and a bump, the first surrounding wall having a first outer surface, a first inner surface opposite to the first outer surface, and a first edge surface connecting between the first outer and inner surfaces oppositely of the first base wall, the first joint unit being disposed on the first edge surface, the first joint unit having a first projecting portion that projects from the first edge surface and that adjoins the first outer surface, a second projection portion that projects from the first edge surface and that adjoins the first inner surface, and a first indentation portion disposed between the first and second projection portions, the bump protruding from the second projection portion oppositely of the first edge surface;

producing a second shell, the second shell including a second base wall, a second surrounding wall connected around the second base wall, and a second joint unit, the second surrounding wall having a second outer surface, a second inner surface opposite to the second outer surface, and a second edge surface connecting between the second outer and inner surfaces oppositely of the second base wall, the second joint unit being disposed on the second edge surface, the second joint unit having a first shoulder portion, a third projection portion, and a second shoulder portion; and

joining the first shell with the second shell, which includes joining the first joint unit with the second joint unit by respectively placing the first projection portion, the first indentation portion and the second projection portion in face to face alignment with the first shoulder portion, the third projection portion and the second shoulder portion and by forming a first bonding layer between the first indentation portion and the third projection portion and a second bonding layer between the second projection portion and the second shoulder portion.

DETAILED DESCRIPTION

Referring toFIGS. 1 to 5, an electronic module10according to an embodiment of the present disclosure includes a first shell1, a second shell2, a first waterproof cable assembly3, and a second waterproof cable assembly4. In this embodiment, while not shown, an integrated circuit board with electronic components is disposed within the first shell1.

The first shell1includes a first base wall11, a first surrounding wall12connected around the first base wall11, a first joint unit13, and a bump14. In this embodiment, but not limited thereto, the first surrounding wall12is four-sided. The first surrounding wall12has a first outer surface121, a first inner surface122opposite to the first outer surface121, and a first edge surface123connecting between the first outer and inner surfaces121,122oppositely of the first base wall11. The first joint unit13is disposed on the first edge surface123. The first joint unit13has a first projection portion131that projects from the first edge surface123and that adjoins the first outer surface121, a second projection portion132that projects from the first edge surface123and that adjoins the first inner surface122, and a first indentation portion133disposed between the first and second projection portions131,132. The bump14is a loop-shaped bump formed on the first shell1. In this embodiment, the bump14protrudes from the second projection portion132in a direction away from the first edge surface123and extends along an entire length of the second projection portion132. However, the configuration of the bump14is not limited only to this embodiment. In addition, while the number of the bump14is one in this embodiment, the number of the bump14is not limited thereto.

Notably, the bump14forms a substantially triangular prism and is tapered in a direction opposite to the first edge surface123of the first surrounding wall12. In this embodiment, the second projection portion132of the first joint unit13has a second projection surface132aextending oppositely of the first inner surface122and adjoining the first indentation portion133. The bump14has a bump outer surface141coplanar with and extending outwardly from an outer end of the second projection surface132aopposite to the first edge surface123, and a bump inner surface142inclined with the bump outer surface141and having one end connected to the bump outer surface141and another end connected to an outer end of the second projection portion132of the first joint unit13opposite to the first edge surface123. While the bump14forms a substantially triangular prism in this embodiment, it is not limited hereto.

Referring toFIGS. 6 and 7, the first shell1further includes a plurality of ribs15protruding from the first edge surface123within the first indentation portion133of the first joint unit13. Each rib15is shorter than the first projection portion131and the second projection portion132of the first joint unit13. In an alternative embodiment of the present disclosure, the ribs15may protrude from the second shell2, or may be omitted.

Further, the ribs15are parallel and equidistantly spaced apart from each other and are transverse to the first inner surface122. Each rib15is tapered in a direction away from the first edge surface123and forms, but not limited to, a substantially triangular prism. In addition, while the ribs15of this embodiment protrude from the first edge surface123on four sides of the surrounding wall12, the ribs15can protrude from at least parts of the first edge surface123located on at least two sides of the surrounding wall12.

The second shell2covers the first shell1and includes a second base wall21, a second surrounding wall22connected around the second base wall21, and a second joint unit23. The second surrounding wall22has a second outer surface221, a second inner surface222opposite to the second outer surface221, and a second edge surface223connecting between the second outer and inner surfaces221,222oppositely of the second base wall21. The second joint unit23is disposed on the second edge surface223to be joined with the first joint unit13. In this embodiment, the second joint unit23has a first shoulder portion231, a third projection portion232, and a second shoulder portion233arranged sequentially from the second outer surface221to the second inner surface222. The first shoulder portion231is aligned with the first projection portion131of the first joint unit13. The third projection portion232is aligned with the first indentation portion133. The second shoulder portion233is aligned with the second projection portion132. In such a manner, the first projection portion131, the first indentation portion133and the second projection portion132respectively and complementarily match the first shoulder portion231, the third projection portion232and the second shoulder portion233.

Referring toFIGS. 8 to 10, in combination withFIG. 1, the first waterproof cable assembly3includes a first cable31, a first seal ring32and a first engagement member33. The first cable31has a first cable portion311. The first cable portion311has a first mounting cable segment311a, a first inner stop segment311band a first outer stop segment311c. The first inner and outer stop segments311b,311care disposed respectively on two opposite sides of the first cable mounting segment311a. Each of the first inner and outer stop segments311b,311chas a width greater than an outer diameter of the first mounting cable segment311a. The first seal ring32is disposed around the first cable mounting segment311aproximately of the first inner stop segment311band between the first inner and outer stop segments311b,311c.

In this embodiment, the first shell1further includes a first cable receiving unit16. The first cable receiving unit16includes a first cable recess161that is indented from the first edge surface123of the first surrounding wall12and that extends transversely through the first outer and inner surfaces121,122of the surrounding wall12. The second shell2further includes a second cable receiving unit24to combine with the first cable receiving unit16. The second cable receiving unit24includes a second cable recess241that is indented from the second edge surface223of the second surrounding wall22and that extends transversely through the second outer and inner surfaces221,222. The first and second cable recesses161,241complement each other to form a hole (h) generally conforming to a cross section of the first cable mounting segment311aand receiving a portion of the first cable mounting segment311abetween the first seal ring32and the first outer stop segment311csuch that each of the first and second surrounding walls12,22is located between the first seal ring32and the first outer stop segment311c. The first engagement member33is wedged between the first surrounding wall12and the first outer stop segment311cand between the second surrounding wall22and the first outer stop segment311cand engages the first cable mounting segment311asuch that the first seal ring32is compressed to seal a clearance between the first cable mounting segment311aand the first surrounding wall12and between the first cable mounting segment311aand the second surrounding wall22. In this embodiment, a sum of original thicknesses of the first seal ring32, the first or second surrounding wall12or22and the first engagement member33is slightly greater than a distance between the first inner stop segment311band the first outer stop segment311c. Therefore, the first ring32is tightly compressed between the first inner stop segment311band the first inner surface122and between the first inner stop segment311band the second inner surface222after the first engagement member33is placed in its wedged position. An inner space7surrounded by the first and second shells1,2is isolated from the ambient environment.

As shown inFIGS. 1 and 10, the engagement member33has a bridge section331lying over and engaging a top side of said first cable mounting segment311aand two first resilient engagement arms332extending respectively and downwardly from two opposite sides of the bridge section331to engage two opposite sides of said first cable mounting segment311a. The first resilient engagement arms332respectively have barb portions332aengaging a bottom side of the first cable mounting segment311a. The barb portions332aare slanted inwardly in two opposite inward directions, respectively. The first cable receiving unit16further includes a first limit wall162extending outwardly from the first outer surface121of the first surrounding wall12and around the first cable recess161. The second cable unit24further includes a second limit wall242extending outwardly from the second outer surface221of the second surrounding wall22and around the second cable recess241. The first limit wall162and the second limit wall242complement each other to surround a limit space8that is adjacent to the first and second outer surfaces121,221and that receives the first outer stop segment311cof the first cable31and the first engagement member33. The second limit wall242has an insertion hole242athat is disposed proximally to the second outer surface221and distally from the second edge surface223of the second surrounding wall22and that communicates with the limit space8. The first engagement member33is inserted into the limit space8through the insertion hole242a.

The second waterproof cable assembly4is structurally similar to the first waterproof cable assembly3. The first shell1further includes a third cable receiving unit17that is structurally similar to the first cable receiving unit16. The second shell2further includes a fourth cable receiving unit25that is structurally similar to the second cable receiving unit24. The third and fourth cable receiving units17,25complementarily match each other to allow the second waterproof cable assembly4to extend into the space7. In this embodiment, while the third and fourth cable receiving units17,25are located oppositely of the first and second cable receiving units16,24, the disposition thereof is not limited hereto. In addition, the number of the waterproof cable assemblies and the cable receiving units are not limited hereto.

Referring back toFIGS. 1, 3, 4 and 5, the first and second shells1,2are coupled with each other by ultrasonic welding to join the first and second joint units13,23. In this embodiment, the first joint unit13of the first shell1is aligned and contacts with the second joint unit23of the second shell2. In other words, the first projection portion131, the first indentation portion133and the second projection portion132of the first joint unit13are placed in face to face alignment or contact with and complementarily match the first shoulder portion231, the third projection portion232and the second shoulder portion233of the second joint unit23, respectively. By ultrasonic welding that simultaneously causes the ribs15and the bump14to frictionally rub the second joint unit23and to melt between the first and second joint units13,23, a first bonding layer5is formed between the first indentation portion133of the first joint unit13and the third projection portion232of the second joint unit23, and a second bonding layer6is formed between the second projection portion132of the first joint unit13and the second shoulder portion233of the second joint unit2. By virtue of the first bonding layer5that joins the first and second joint units13,23and the second bonding layer6that enhances the joint between the first and second joint units13,23, fluid (such as vapors, glue, melt etc.) can be prevented from entering the inner space7of the electronic module10. Furthermore, the phenomenon of melt overflow can be prevented if the first and second joint units13,23deeply mesh with each other. Incase the level of the intermeshing of the first and second joint units13,23is shallow, when undergoing drop and falling ball tests, the electronic module10is still able to pass the tests. Therefore, the connection between the first and second joint units13,23not only enables the electronic module10to pass the drop and falling ball tests, but al so prevents fluid from entering therein. Further, the second bonding layer6formed by the bump14is capable of avoiding problems of electro-static discharge (ESD). In this embodiment, while the first and second shells1,2are joined with each other by ultrasonic welding, the way of joining the first and second sells1,2is not limited hereto. In addition, if the ribs15are to be omitted, the first and second shells1,2may be bonded to each other with adhesive. For example, the first indentation portion133may fill with an adhesive to adhere the first and second shells1,2together.

Referring back toFIGS. 1, 8, 9 and 10, because it is the same to install the first and second waterproof cable assemblies3,4, herein exemplified is installation of the first waterproof cable assembly3. First, the first cable portion311of the first cable31surrounded by the first seal ring32is placed in the first cable receiving unit16. In this situation, the first cable mounting segment311ais placed in the first cable recess161. The first inner stop segment311band the first seal ring32are disposed proximally of the first inner surface122, and the first seal ring32is disposed between the first inner stop segment311band the first inner surface122. The first outer stop segment311cis disposed proximally of the first outer surface121. Subsequently, the first and second shells1,2are joined with each other by ultrasonic welding, such that the first and second cable recesses161,241complement each other to form the hole (h). The first cable mounting segment311aextends through the hole (h). The first inner stop segment311band the first seal ring32are disposed inwardly of the first and second surrounding walls12,22, and the first outer stop segment311cis disposed outwardly of the first and second surrounding walls12,22and received within the limit space8. Afterwards, the first cable31is pulled outward in a direction away from the first and second outer surfaces121,221so that the first inner stop segment311b, the first inner surface122and the second inner surface222cooperatively compress the first seal ring32, and a distance of the first outer stop segment311cfrom the first and second outer surfaces121,222is enlarged. At this stage, through the insertion hole242aof the second limit wall242, the first engagement member33is inserted into the limit space8and is wedged between the first outer surface121and the first outer stop segment311cand between the second outer surface222and the first outer stop segment311c, and the engagement member33therefore engages the first cable mounting segment311a. The bridge section331of the first engagement member33is situated in the insertion hole242a. The first engagement member33provides a pressure that compresses the first seal ring32via the first inner stop segment311band the first and second inner surfaces122,222to seal the clearance between the first cable mounting segment311aand the first inner surface122and between the first cable mounting segment311aand the second inner surface222, thereby preventing a fluid from flowing into the inner space7.

Notably, in this embodiment, the electronic module10is, but not limited to, a voltage converter and further includes a voltage converting unit (not shown) connecting between the first and second waterproof cable assemblies3,4.

In summary, because the first and second bonding layers5,6are formed by ultrasonic welding which causes the ribs15and the bump14to frictionally rub the second joint23and to melt between the first and second joint units13,23, not only the joining structure of the electronic module10can be strengthened, but the ESD problem can be avoided. Further, by virtue of the structural arrangement of the first and second shells1,2cooperating with the first and second waterproof cable assemblies3,4, the clearance formed between the first and second shells1,2is sealed to prevent a fluid from flowing therethrough into the electronic module10.