Electrical Assembly Dual Adhesive Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical assemblies face mechanical stress issues during handling and processing, leading to failures in the electrical and mechanical connections between components and leads, and there is a risk of electrical shorting due to conductive adhesives.
Innovation Solution
The use of non-electrically conductive adhesive members to mechanically connect leads to an electrical component, combined with electrically conductive adhesive members for electrical connectivity, providing a robust mechanical and electrical connection that withstands stress and prevents shorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrically conductive epoxy is used to join leads to electrical component, then electrical connection is achieved, but mechanical strength is insufficient and electrical shorting may occur
Solution Approach 1:
The patent divides the adhesive function into two separate adhesive members: a first adhesive member for mechanical bonding and a second adhesive member for electrical conduction. This segmentation allows each adhesive member to be optimized for its specific function, preventing the mechanical strength deficiency and electrical shorting issues that occur when a single conductive adhesive is used for both purposes.
Solution Approach 2:
The first non-conductive adhesive member acts as an intermediary mechanical bonding layer between the lead and electrical component, providing robust mechanical strength. The second conductive adhesive member then provides the electrical connection pathway. This intermediary approach separates the mechanical and electrical functions, eliminating the risk of electrical shorting through the mechanical bonding layer.
2Reliability
If electrically conductive epoxy is used to join leads to electrical component, then electrical connection is achieved, but electrical shorting risk increases
Solution Approach 1:
By segmenting the adhesive system into a non-conductive first adhesive member and a conductive second adhesive member, the patent eliminates the harmful effect of electrical shorting. The non-conductive first adhesive member provides mechanical bonding without creating electrical pathways, while the conductive second adhesive member provides controlled electrical connection only where needed.
Solution Approach 2:
The patent applies local quality by making the adhesive members have different electrical conductivity properties at different locations. The first adhesive member is non-conductive to prevent shorting, while the second adhesive member is conductive to enable electrical connection. This localized property differentiation resolves the electrical shorting risk while maintaining reliable electrical connection.
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 enhances the mechanical strength of electrical assemblies, preventing connection failures and reducing the likelihood of electrical shorting, thereby improving the reliability and durability of the assemblies during handling and processing operations.
Implementation Method 1
A first non-electrically conductive adhesive member joins the first lead to the first end of the electrical component such that the first non-electrically conductive adhesive member mechanically connects the first lead to the first end of the electrical component
Implementation Method 2
A first electrically conductive adhesive member joins the first lead to the first end of the electrical component such that the first electrically conductive adhesive member electrically connects the first lead to the first end of the electrical component
Data Source
AI summary
An electrical assembly includes a first lead, a second lead, and an electrical component extending from a first end to a second end. A first non-electrically conductive adhesive member mechanically connects the first lead to the first end of the electrical component. A second non-electrically conductive adhesive member mechanically connects the second lead to the second end of the electrical component. A first electrically conductive adhesive member electrically connects the first lead to the first end of the electrical component. A second electrically conductive adhesive member electrically connects the second lead to the second end of the electrical component.