Fluidic Seal for Window Electrical Connections
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Solution Overview
Problem
Window assemblies with electrical connections face mechanical stress and water ingress issues due to polymeric encapsulation, leading to corrosion and failure of electrical joints, especially in exposed environments like vehicles and buildings.
Innovation Solution
A fluidically sealed enclosure is created using a sealing material that fills the internal volume around the electrical joint, reducing mechanical stress and preventing water ingress, with the enclosure adhered to the transparent pane using structural bonding tape or pressure-sensitive adhesive, and the sealing material contacting the enclosure walls to form a fluidic barrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymeric encapsulation is used to protect the solder joint, then protection from elements is improved, but mechanical stress on the solder joint increases
Solution Approach 1:
The patent introduces an intermediary flexible barrier layer between the rigid enclosure and the solder joint. This barrier layer absorbs mechanical stress from thermal expansion differences, preventing stress transmission to the solder joint while maintaining environmental protection. The barrier layer acts as a stress-absorbing intermediary that decouples the rigid enclosure from the sensitive electrical components.
2Reliability
If polymeric encapsulation is used to protect the solder joint, then protection from elements is improved, but water ingress through the encapsulation occurs
Solution Approach 1:
The patent employs a flexible barrier layer made of elastomeric material that forms a water-tight seal around the solder joint and wiring harness. This flexible film conformally encapsulates the components, preventing water ingress while accommodating mechanical movements and thermal expansions without cracking or delamination.
3Strength
If rigid enclosure is used to protect electrical connections, then structural protection is improved, but stress concentration on electrical joints occurs
Solution Approach 1:
The patent segments the enclosure system into multiple functional layers: a rigid outer enclosure for structural protection, a flexible intermediate barrier layer for stress absorption, and a conformal seal layer for environmental protection. This segmentation allows each layer to perform its specific function without transferring stress to the electrical joints.
Solution Approach 2:
The flexible barrier layer acts as a stress-absorbing interface between the rigid enclosure and the electrical components. This thin film accommodates dimensional changes and mechanical stresses, preventing stress concentration on the solder joint while maintaining the structural integrity of the overall enclosure system.
Data Source
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AI summary
According to aspects of the present disclosure, a method of environmentally sealing an electrical joint formed between an electrical connection element and an electrical conductor disposed on a transparent pane is described. The method includes adhering a mechanically protective enclosure to the transparent pane to define an internal volume therebetween and filling at least a portion of the internal volume with a sealing material that inhibits ingress of liquid into the volume and provides a fluidic environmental barrier about the electrical joint. The electrical joint is disposed within the internal volume and spaced from the enclosure.