Cover Plate Electrical Bonding for Vibration-Resistant Vehicle Modules
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Solution Overview
Problem
Existing electrical units in motor vehicles, such as lighting devices and sensor devices, face issues with connector looseness due to vibrations or shocks, leading to contact loss, corrosion, and high installation effort, which restricts design freedom and is not aesthetically pleasing.
Innovation Solution
The electrical unit features a housing with pockets for electrical contact means from a separate control unit, and a cover plate with pins for the electrical module, where an electrically conductive joining means forms a substance-to-substance bond between the pins and pockets, creating a permanent, vibration-resistant connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connector is used to connect the electrical module to the control unit, then the electrical connection can be established, but the connector becomes loose due to vibrations or shocks, reducing contact surface or causing complete loss of contact
Solution Approach 1:
The patent removes the separate connector component from the system and replaces it with direct substance-to-substance bonding between contact pins and contact surfaces. This extraction of the connector eliminates the interface that was prone to loosening under vibration and shock, while maintaining electrical connectivity through the bonding agent.
Solution Approach 2:
The patent merges the mechanical connection function and electrical connection function into a single integrated bonding structure. The bonding agent simultaneously provides mechanical adhesion to prevent loosening and electrical conductivity to maintain circuit connectivity, eliminating the need for separate mechanical and electrical connection components.
2Reliability
If a connector is used to connect the electrical module to the control unit, then the electrical connection can be established, but corrosion can occur on exposed portions of individual contact pins and local burn-off can occur due to high contact resistance
Solution Approach 1:
The patent extracts the exposed contact surfaces that were previously visible and vulnerable to environmental damage. By embedding the contact pins and contact surfaces within the bonding agent, the system eliminates direct exposure to corrosive environments while maintaining electrical conductivity through the bonding medium.
Solution Approach 2:
The patent employs a composite bonding agent that combines multiple functional properties: mechanical adhesion to secure the connection, electrical conductivity to transmit current, and environmental protection to prevent corrosion. This multi-functional composite material simultaneously addresses mechanical stability and protection against harmful environmental factors.
3Reliability
If a connector is used to connect the electrical module to the control unit, then the electrical connection can be established, but the connector is visible from the outside behind the cover plate, restricting design freedom and aesthetic appeal
Solution Approach 1:
The patent removes the visible connector component from the external view by eliminating the separate connector piece entirely. The electrical connection is achieved through internal bonding that is not visible from outside the cover plate, allowing for cleaner aesthetic design while maintaining functional electrical connectivity.
4Reliability
If a connector is used to connect the electrical module to the control unit, then the electrical connection can be established, but attaching the connector to the cover plate requires high installation effort and cannot be easily automated
Solution Approach 1:
The patent combines the electrical connection establishment with the cover plate attachment process itself. The bonding agent serves dual purposes: securing the cover plate to the housing and establishing electrical connections simultaneously. This merging of functions eliminates the separate connector attachment step, enabling automation through standard bonding processes.
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
This solution ensures a reliable, low-resistance electrical connection between the electrical module and the control unit, resistant to vibrations and shocks, while also improving aesthetic appeal and reducing installation complexity.
Implementation Method 1
an electrically conductive joining means, such that an electrical connection is formed between the electrical module and the control unit
Data Source
AI summary
The present invention relates to an electrical unit, in particular a lighting device or a sensor device of a motor vehicle, having a cover plate or a cover plate assembly. At least one electrical module is arranged on the cover plate or the cover plate assembly, in particular a heating module, a light module or a sensor module. The electrical module is operable by a separate control unit. A housing of the unit has at least two pockets into which electrical contacts of the control unit enter. The cover plate or the cover plate assembly has at least two pins on which electrical contacts of the electrical module are arranged, wherein the pins project into the pockets and are connected thereto by an electrically conductive joining means in a substance-to-substance bonding manner in such a way that an electrical connection is formed between the electrical module and the control unit.