Flexible Circuit Connector Sealing for Moisture-Proof Flat Wires
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Solution Overview
Problem
Flexible circuit connections without insulating bodies are susceptible to moisture ingress, compromising the reliability of electrical connections in vehicles.
Innovation Solution
A watertight compression seal system that contours to the connection area of flexible circuits, using a seal surrounding a cavity in the electrical connector to create an impermeable interface between connector terminals and flat-wire conductors, with a retainer compressing the seal to form a watertight connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the insulating body is removed to simplify the structure and reduce cost, then the manufacturing complexity is reduced, but the connection area becomes susceptible to moisture ingress
Solution Approach 1:
The connector is divided into two separate portions: a connector portion with electrical terminals and a separate watertight seal portion. This segmentation allows the seal to be independently designed and applied only where moisture protection is needed, without requiring a complex insulating body structure.
Solution Approach 2:
A separate watertight seal acts as an intermediary element between the connector terminals and the flexible circuit connection area. This seal specifically addresses the moisture protection function without adding overall structural complexity to the connector assembly.
2Reliability
If a watertight seal is added to protect against moisture, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The watertight seal portion is designed to be integrated with the connector portion through a unified retainer structure that attaches both components simultaneously. This merging approach ensures the seal is properly positioned and secured without adding separate complex assembly mechanisms.
Solution Approach 2:
The watertight seal utilizes a flexible seal member that can conform to the connection area geometry. This flexible film approach provides effective moisture protection while maintaining a simple, lightweight structure that doesn't significantly increase overall device complexity.
3Reliability
If the seal is compressed to form a watertight connection, then the moisture protection is improved, but the flexible circuit may be damaged
Solution Approach 1:
The compression force is applied locally and specifically to the seal member rather than uniformly across the entire flexible circuit. The retainer structure is designed to concentrate the compressive force on the seal portion that contacts the connection area, protecting the flexible circuit from excessive or distributed compression damage.
Solution Approach 2:
The seal member is pre-positioned in a groove or recess that provides a controlled compression interface. This beforehand positioning ensures that when compression is applied, the force is distributed appropriately to create a watertight seal without exceeding the damage threshold of the flexible circuit conductors.
4Ease of operation
If the connection area is exposed for easy connector attachment, then the ease of operation is improved, but the susceptibility to moisture ingress increases
Solution Approach 1:
The watertight seal is pre-installed on the connector portion before attachment to the flexible circuit. This preliminary action ensures that the seal is already in place and properly positioned, so that when the connector is attached to the exposed connection area, moisture protection is immediately established without requiring additional protective measures.
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 system effectively prevents moisture ingress, ensuring reliable electrical connections without damaging the flexible circuit and allowing for reusability of the seal.
Implementation Method 1
a retainer is fitted over the flexible circuit and attached to the watertight electrical connector to compress the seal and form the watertight connection
Data Source
AI summary
A watertight electrical connection system to flat-wire conductors of a flexible circuit is described including a watertight electrical connector that houses connector terminals within a cavity. A contact surface of the watertight electrical connector is configured to mate with a connection area on a surface of the flexible circuit. The connection area is of variable thickness. A seal surrounds an opening to the cavity to form a watertight connection between the connector terminals and one or more of the flat-wire conductors within the connection area on the surface of the flexible circuit. A retainer fits over the flexible circuit and onto the watertight electrical connector to compress the seal and form the watertight connection between the surface of the flexible circuit and the contact surface, which is of variable thickness.