Angled Plug Receptacle for Window Substrate Connection
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Solution Overview
Problem
Modern motor vehicle windows with fine, electrically conductive structures face mechanical stress and breakage due to differing coefficients of thermal expansion, and existing connection methods are prone to instability and corrosion, especially under shearing forces.
Innovation Solution
A connection arrangement featuring a housing with an adhesive fastening to a substrate, containing plug receptacles with angled plug contacts that absorb forces perpendicular to the substrate, using elastic conductors and contact pads with a clamp connection or rivets, and employing a polymer substrate with a transparent polymer film for durability and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldered metal brackets are used to contact electrically conductive structures, then electrical connection is achieved, but mechanical stability is poor and the connection is susceptible to shearing forces
Solution Approach 1:
The plug receptacle is angled at 15° to 90° relative to the substrate surface, transforming the force direction from parallel (shearing) to perpendicular (compressive) to the substrate. This dimensional change in force application protects the thin electrically conductive structures from shearing forces while maintaining electrical connection stability.
Solution Approach 2:
The housing acts as an intermediary structure that absorbs and redirects insertion forces away from the fragile connection point between the contact pad and electrically conductive structure. The housing's rigid structure protects the soft solder joint from direct mechanical stress.
2Adaptability or versatility
If adapter systems are used to convert connections to metal brackets, then plug format compatibility is achieved, but device complexity increases
Solution Approach 1:
The connection element merges the housing, contact pads, electrical conductors, and plug receptacle into a single integrated component. This eliminates the need for separate adapter systems while maintaining plug format compatibility, thereby reducing device complexity.
Solution Approach 2:
The connection element serves multiple functions: it provides electrical connection, mechanical support, force absorption, and plug compatibility all in one component. This multi-functionality replaces what previously required multiple separate components including adapter systems.
3Illumination intensity
If thin electrically conductive structures are used, then visual perception is improved, but contact point stability is reduced
Solution Approach 1:
By angling the plug receptacle, the insertion force is directed perpendicular to the substrate rather than parallel to the thin electrically conductive structure. This protects the fragile contact point while maintaining the thin, visually imperceptible structure for aesthetic purposes.
Solution Approach 2:
The housing serves as a protective intermediary that shields the thin electrically conductive structure from direct mechanical stress during plug insertion, allowing the use of thin structures for visual reasons without compromising contact stability.
4Ease of operation
If forces act during plug insertion, then electrical connection is established, but mechanical stress strains the substrate and may cause breakage
Solution Approach 1:
The angled plug receptacle (15° to 90°) redirects insertion forces from a horizontal direction that would strain the substrate to a vertical direction where the substrate's compressive strength is maximized, preventing breakage during plug insertion.
Solution Approach 2:
The housing acts as a force-absorbing intermediary that intercepts and manages insertion forces before they can be transmitted to the substrate, protecting the substrate from stress-induced breakage while still enabling easy plug insertion.
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 solution provides a stable and durable electrical connection that reduces mechanical stress and corrosion, allowing for efficient assembly and increased production throughput while maintaining electrical conductivity and resistance to environmental factors.
Implementation Method 1
the housing that is bonded on its bottom to the substrate by an adhesive fastening
Data Source
AI summary
A connection assembly is described. The connection assembly has a substrate having at least two electrically conductive structures, a housing, which is connected to the substrate on the bottom by an adhesive fastening, the housing has a plug receptacle having at least two plug contacts, the plug contacts are connected to at least two contact pads via electrical conductors, and the contact pads connected in an electrically conducting fashion to the electrically conductive structures, the angle between the plug-in direction into the plug receptacle and the bottom of the housing lying between 15° to 90°.