Dual-Seal Electrical Connection for Windscreen Thermal Stress
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Solution Overview
Problem
Electrical connections in heated windscreen assemblies face challenges in withstanding environmental conditions such as water, thermal cycling, and physical shocks, leading to potential corrosion and reduced efficiency, and require accurate location and durability during installation and use.
Innovation Solution
The electrical connection employs a dual-seal system with a first seal encasing the electrical cable and a second seal contacting the insulated portion of the connector, both made from resilient adhesive materials, encased within a thermoplastic enclosure to provide a robust, fluid-tight seal and protect against corrosion and physical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If a single seal is used to connect the electrical cable to the flat connector, then the enclosure size is reduced, but the connection robustness and sealing effectiveness deteriorate
Solution Approach 1:
The sealing system is divided into two distinct seals: a first seal that encircles the electrical cable and a second seal that contacts the insulated portion of the flat connector. This segmentation allows each seal to perform its specific function optimally, creating a more robust sealing system while maintaining a compact enclosure size.
Solution Approach 2:
The first seal acts as an intermediary element between the electrical cable and the enclosure, providing a secure seal around the cable. The second seal then acts as an intermediary between the connector and the enclosure. These intermediary seals ensure that the enclosure remains compact while maintaining robust connections.
2Productivity
If the electrical connection is formed early and affixed to the windscreen laminate, then the manufacturing process is streamlined, but the connection is exposed to high autoclave temperatures for extended periods causing potential damage
Solution Approach 1:
The enclosure with its dual-seal system is designed beforehand to provide thermal protection to the electrical connection. The seals and enclosure material act as a cushioning barrier that protects the sensitive electrical components from the high temperatures and prolonged exposure conditions inside the autoclave during windscreen laminate bonding.
Solution Approach 2:
The enclosure utilizes composite material construction combining thermoplastic material with adhesive seals. This composite structure provides both mechanical strength and thermal insulation properties, allowing the electrical connection to withstand autoclave processing temperatures while maintaining sealing effectiveness.
3Device complexity
If the electrical connection is exposed to water and corrosive elements, then the structure remains simple, but corrosion occurs leading to increased resistance and connection failure
Solution Approach 1:
The dual-seal system employs flexible adhesive seals that conform to the cable and connector surfaces, creating a tight barrier against water and corrosive elements. The first seal forms a flexible barrier around the cable, while the second seal creates a flexible seal at the connector interface, together providing comprehensive corrosion protection.
Solution Approach 2:
The sealing structure uses a nested arrangement where the first seal encircles the electrical cable, and the second seal encircles the connector with the first seal nested within the overall sealing system. This nested configuration creates multiple barriers against corrosive elements, enhancing protection without significantly increasing structural complexity.
4Manufacturing precision
If accurate location of the electrical cable relative to the flat connector is required, then connection precision is improved, but the positioning process becomes more complex
Solution Approach 1:
The first seal is applied to the electrical cable in advance, creating a predetermined positioning feature. This preliminary action establishes a reference point that guides the accurate location of the cable relative to the flat connector during assembly, improving positioning accuracy without requiring complex positioning mechanisms.
Solution Approach 2:
The dual-seal system provides self-aligning and self-positioning characteristics. The first seal on the cable and the second seal on the connector work together to automatically establish the correct relative position during assembly, enabling accurate cable location without requiring complex external positioning equipment or 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
The dual-seal system effectively prevents water ingress and corrosion, maintains electrical integrity under thermal and mechanical stress, and ensures accurate cable positioning, enhancing the durability and reliability of the electrical connection.
Implementation Method 1
The first seal (and/or second seal) may comprise an adhesive material, e.g. such that the first and/or second seal may be secured to the electrical cable and/or the flat connector respectively
Implementation Method 2
the first seal may be configured to resiliently contact the enclosure and/or may comprise a resilient material
Implementation Method 3
The electrical connection is commonly formed and affixed to the windscreen laminate at a prior stage and is hence located within the autoclave during bonding. As a result it is essential that the electrical connection is able to withstand the 150°C temperature within the autoclave
Data Source
Figure 1A~1C
Figure 2A~2D
Figure 3~4B
AI summary
An electrical connection 1 for electrically connecting a flat connector 2 and an electrical cable 3, the electrical connection 1 comprising a flat connector 2 with an insulated portion 21 and an exposed electrically conductive portion 20e, an electrical cable 3, a first seal 6a, a second seal 6b and an enclosure 4, wherein the flat connector 2 and the electrical cable 3 are secured together in order to provide electrical contact between one another at the exposed electrically conductive portion 20e of the flat connector 2, the first seal 6a being outboard of the exposed electrically conductive portion 20e of the flat connector 2 and adjacent a distal edge of the exposed electrically conductive element 20 of the flat connector 2, whereby the enclosure 4 encases the first seal 6a and the electrical contact.