Dash Panel Ground Block Using Strippable Conductive Patch

Solution Overview

Problem

The existing process of grounding motor vehicle electrical systems by mechanically stripping paint and primer from the dash panel to establish electrical contact is inefficient, creating dust and potential rusting issues, and is inconsistent.

Innovation Solution

Applying a strippable patch with dielectric or conductive grease or pads to the dash panel before painting, which remains in contact with the bare metal and allows for secure electrical connection when the ground block is mounted, eliminating the need for mechanical abrasion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mechanical abrasion is used to strip paint and primer from the dash panel, then electrical contact between the ground block and dash panel is established, but dust is created and bare metal is exposed to rusting

Engineering Contradiction:

Improveelectrical contactVSAvoiddust and rusting

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The grease is applied to the bare metal surface before painting, creating a protective layer that remains in place throughout the painting process. This preliminary action eliminates the need for later mechanical stripping, as the grease maintains electrical conductivity while protecting the metal from rust and preventing paint adhesion in the grounding area.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical abrasion process is replaced with a chemical/adhesive approach using grease and the strippable patch system. Instead of mechanically removing paint through abrasion, the grease's adhesive properties and the patch's controlled removal mechanism achieve the same goal without creating dust or exposing bare metal to rust.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If mechanical abrasion is used to strip paint and primer, then electrical contact is established, but the process is inconsistent from truck to truck

Engineering Contradiction:

Improveelectrical contactVSAvoidprocess consistency

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The grease is applied to the bare metal surface before painting, creating a protective layer that remains in place throughout the painting process. This preliminary action eliminates the need for later mechanical stripping, as the grease's adhesive properties and the patch's controlled removal mechanism achieve the same goal without creating dust or exposing bare metal to rust.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical abrasion process is replaced with a chemical/adhesive approach using grease and the strippable patch system. Instead of mechanically removing paint through abrasion, the grease's adhesive properties and the patch's controlled removal mechanism achieve the same goal without creating dust or exposing bare metal to rust.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If paint and primer are removed by mechanical action, then electrical contact is achieved, but time and labor are consumed

Engineering Contradiction:

Improveelectrical contactVSAvoidpaint stripping time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The grease is applied to the bare metal surface before painting, creating a protective layer that remains in place throughout the painting process. This preliminary action eliminates the need for later mechanical stripping, as the grease's adhesive properties and the patch's controlled removal mechanism achieve the same goal without creating dust or exposing bare metal to rust.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical abrasion process is replaced with a chemical/adhesive approach using grease and the strippable patch system. Instead of mechanically removing paint through abrasion, the grease's adhesive properties and the patch's controlled removal mechanism achieve the same goal without creating dust or exposing bare metal to rust.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method ensures consistent and reliable electrical contact between the ground block and the dash panel, reducing dust and rusting risks while maintaining paint integrity.

Implementation Method 1

The outer perimeter margin of the inner surface contains an adhesive for adhering to the dash panel

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

Dielectric grease and/or conductive grease is present on a zone of the inner surface of the cover whose perimeter is bounded by the adhesive

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

The grease has sufficient tenacity with the bare metal that a layer of grease remains on the bare metal as the cover is being peeled off

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS8038821B2Preparing a pass-through for an occupant compartment—engine compartment ground block

Publication Date: 2011.10.18 INT TRUCK INTPROP CO LLC

AI summary

A special patch is adhered to the bare metal of a dash panel in covering relation to one or more pass-through holes and their margins before a truck cab is primed and painted. After painting, a cover of the patch is peeled off to expose an electrically conductive medium that remains adhered to the bare metal. A ground block is mounted on the dash panel with a stud passing through a pass-through hole. The electrically conductive medium establishes conductivity of the body of the ground block to the dash panel.