Circuit Unit Waterproofing via Dual Resin Segmentation
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Solution Overview
Problem
Existing waterproofing techniques for circuit units do not effectively prevent water entry from the terminal portion to the electronic component side, particularly around busbars within the waterproof case.
Innovation Solution
A circuit unit configuration that includes a first waterproofing portion made of resin with an adhesive component in intimate contact with the busbar and a second waterproofing portion made of resin covering the outer surfaces, preventing water entry by blocking it at both the terminal and body portions, with additional features such as recesses and through holes on the busbar for improved adhesion and fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a waterproofing portion is provided around the external connection terminal inside the hood portion, then water entry at the terminal connection point is prevented, but water can still enter from the interface between the external connection terminal and the waterproofing portion around the busbar
Solution Approach 1:
The waterproofing structure is divided into two distinct portions: a first waterproofing portion made of resin with adhesive component that contacts the busbar surface, and a second waterproofing portion made of waterproof resin that provides the main sealing barrier. This segmentation allows each portion to perform its specific function optimally, preventing water entry at the busbar interface while maintaining structural integrity.
Solution Approach 2:
The first waterproofing portion made of resin containing adhesive component acts as an intermediary between the busbar and the second waterproofing portion. It provides strong adhesion to the busbar surface and creates a seamless transition zone that prevents water from penetrating to the interface between the external connection terminal and the waterproofing structure.
2Reliability
If a resin waterproofing portion is used without adhesive component, then waterproofing is achieved, but adhesion to the busbar and positional stability are insufficient
Solution Approach 1:
The waterproofing system is segmented into two functional portions: the first portion made of resin with adhesive component that provides strong bonding to the busbar, and the second portion made of waterproof resin that provides the sealing function. This segmentation resolves the contradiction by assigning adhesion and waterproofing functions to different portions.
Solution Approach 2:
The first waterproofing portion uses composite material properties by combining resin with adhesive components, creating a material that exhibits both adhesive strength and waterproofing characteristics. This composite approach allows the waterproofing structure to achieve both strong adhesion and effective water sealing.
3Adaptability or versatility
If the terminal portion has a large width dimension, then connection capability is improved, but waterproofing becomes difficult without gaskets
Solution Approach 1:
The invention replaces the mechanical gasket-based waterproofing system with a resin-based chemical bonding system. The resin waterproofing portions can adapt to large terminal width dimensions through their flow and curing characteristics, eliminating the need for separate gasket components and simplifying the waterproofing implementation for large-terminal configurations.
Solution Approach 2:
The waterproofing approach changes from mechanical (gaskets) to chemical (resin bonding), allowing the waterproofing structure to accommodate varying terminal dimensions including large width dimensions. The resin material properties can be adjusted to match different terminal geometries, providing versatile waterproofing without requiring gasket modifications.
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
Effectively inhibits water entry from the terminal side to the electronic component side, enhancing adhesion and positional stability of the waterproofing portions, and allowing for waterproofing without the need for gaskets, even with larger terminal dimensions.
Implementation Method 1
a first waterproofing portion that is in intimate contact with a portion to be waterproofed located between the body portion and the terminal portion of the circuit section, and that includes a resin containing an adhesive component
Data Source
AI summary
Entry of water from the terminal portion side to the electronic component side is inhibited. A circuit unit includes: a circuit section including a terminal portion that can be connected to an external terminal, and a body portion to which an electronic component is mounted; a first waterproofing portion that is in intimate contact with a portion to be waterproofed located between the body portion and the terminal portion of the circuit section, and that includes a resin containing an adhesive component; and a second waterproofing portion that is in intimate contact with an outer surface of each of the circuit section and the first waterproofing portion, and that is made of a resin.