Flat Connector Cable Joint With Adhesive Sealing Against Water Ingress
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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, especially during the high-temperature autoclave bonding process.
Innovation Solution
An electrical connection system featuring a flat connector with a pressure-sensitive adhesive window and an encased electrical contact, using a lead-free solder and a thin layer of non-conductive material, which provides enhanced sealing and resistance to water ingress, and is designed to withstand extreme temperatures and physical stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the electrical connection is exposed to environmental conditions (water, thermal cycling, humidity), then the electrical connection can be simple in structure, but corrosion occurs leading to increased resistance and reduced efficiency
Solution Approach 1:
The patent introduces an adhesive layer as an intermediary between the electrical contact and the environment. This adhesive layer acts as a protective barrier that prevents direct contact between corrosive elements (water, humidity, chemicals) and the electrical connection, thereby preventing corrosion without requiring complex protective structures. The adhesive mediates between the simple electrical connection design and the need for environmental protection.
2Productivity
If the electrical connection is located within the autoclave during bonding, then the electrical connection can be formed early in the process, but the adhesive must withstand 150°C temperature for around three hours
Solution Approach 1:
The patent selects an adhesive with specific thermal parameters that allow it to withstand the autoclave bonding conditions (150°C for around three hours). The adhesive's glass transition temperature and thermal stability are specifically chosen to maintain its bonding properties throughout the high-temperature curing process, enabling early formation of the electrical connection within the autoclave without compromising the adhesive joint.
3Reliability
If a thick layer of adhesive is used to seal the electrical contact, then water ingress is prevented, but the electrical connection size increases
Solution Approach 1:
The patent employs a thin film of adhesive that provides effective sealing against water ingress. The adhesive layer is sufficiently thin to minimize volume increase of the electrical connection, yet sufficiently continuous and compliant to prevent water penetration. The flexible nature of the thin adhesive film allows it to conform to the electrical contact geometry while maintaining an effective barrier against environmental moisture.
4Strength
If the electrical connection is designed to withstand physical shocks during installation and use, then the electrical connection can be durable, but the structure becomes more complex
Solution Approach 1:
The patent creates a composite structure where the adhesive material combines bonding, sealing, and shock-absorbing properties. This single composite adhesive layer integrates multiple functions: it bonds the electrical contact to the substrate, seals against environmental ingress, and provides mechanical compliance to absorb physical shocks during installation and use, thereby achieving shock resistance without increasing overall structural complexity.
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 effectively prevents water ingress and corrosion, ensuring a robust and durable electrical connection that maintains efficiency even under extreme conditions, including high temperatures and physical shocks, as demonstrated by successful insulation resistance and bending cycle tests.
Implementation Method 1
a flat connector with an insulated portion and an electrically conductive portion to which is secured a pressure sensitive adhesive defining a window
Implementation Method 2
using a lead-free solder
Data Source
AI summary
An electrical connection (1) for electrically connecting a flat connector (2) and an electrical cable (3), the electrical connection (1) includes a flat connector (2) with an insulated portion (21) and an electrically conductive portion (20e) to which is secured a pressure sensitive adhesive (6) defining a window (6w), an electrical cable (3) which is secured to the flat connector (2) at the window (6w) to provide an electrical contact between the flat connector (2) and the electrical cable (3), and an enclosure (4) encasing the electrical contact.