Flat Connector Cable Joint With Adhesive Window Sealing

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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 improved resistance and durability.

Innovation Solution

An electrical connection is designed with a flat connector having an insulated portion and an exposed conductive portion secured with a pressure-sensitive adhesive, forming a window for the electrical cable contact, which is then encased in an enclosure, utilizing a lead-free solder and pressure-sensitive adhesives to enhance sealing and resistance to water ingress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the electrical connection is exposed to environmental conditions (water, thermal cycling, humidity), then electrical transfer efficiency is maintained initially, but corrosion occurs leading to increased resistance and reduced efficiency

Engineering Contradiction:

Improveelectrical connection durabilityVSAvoidcorrosion from water exposure

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A corrosion-resistant metal layer (such as gold, palladium, or other noble metals) is applied as an intermediary between the base metal and the corrosive environment. This protective layer acts as a barrier that prevents water and other environmental factors from causing corrosion to the electrical connection, thereby maintaining electrical transfer efficiency over time while exposing the connection to necessary environmental conditions for testing and operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The electrical connection employs composite material construction with multiple layers including corrosion-resistant metal coatings over base metal substrates. This composite structure combines the electrical conductivity of the base metal with the corrosion resistance of the outer protective layer, enabling the connection to withstand thermal cycling, humidity, and water exposure without degrading electrical performance.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If the electrical connection is subjected to thermal cycling and physical shocks, then operational flexibility is improved, but structural integrity deteriorates leading to connection failure

Engineering Contradiction:

Improveresistance to thermal cyclingVSAvoidstructural integrity under shock

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The electrical connection utilizes materials and designs that maintain stable electrical and mechanical properties across wide temperature ranges. Corrosion-resistant metal layers are selected for their thermal stability and resistance to thermal expansion/contraction cycling, allowing the connection to adapt to thermal environments without compromising structural integrity during installation and operation.

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If a thick layer of adhesive is used to seal the electrical contact, then protection from water ingress is improved, but the sealing effectiveness is reduced due to improper adhesion

Engineering Contradiction:

Improveprotection from water ingressVSAvoidsealing effectiveness

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The design removes the adhesive layer entirely from the sealing function, extracting the sealing task from chemical adhesion and assigning it to the mechanical enclosure instead. This eliminates the problems associated with thick adhesive layers while maintaining effective protection against water ingress through properly designed physical barriers.

Inventive Principle:

Principle #2Taking out (Extraction)

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 provides a robust and durable electrical connection that withstands thermal cycling, physical shocks, and environmental exposure, maintaining insulation resistance and preventing corrosion, as demonstrated by successful testing under salt water, bending, and thermal cycling conditions.

Implementation Method 1

a pressure sensitive adhesive which defines a window and to which the electrical cable is secured

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

an enclosure encasing the electrical contact

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Implementation Method 3

utilizing a lead-free solder and pressure-sensitive adhesives to enhance sealing and resistance to water ingress

Methodology Applied

Scientific EffectSoldering: Soldering

Data Source

PatentEP4283791A1Electrical connection

Publication Date: 2023.11.29 STRIP TINNING

Figure 1A~1C
Figure 1D
Figure 2A~2E

AI summary

An electrical connection (1) for electrically connecting a flat connector (2) and an electrical cable (3), the electrical connection (1) comprises 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.