Glass-Mounted Electrical Terminal Structure Against Peeling and Cracking
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Solution Overview
Problem
Current electrical terminals used in automotive vehicles are prone to peeling from glass surfaces due to accidental pulling forces and can cause glass cracking during soldering due to heat-related stress concentrations.
Innovation Solution
The electrical terminal design features a planar base portion with a circular perimeter and securing tabs that are bent over an attachment portion, providing a secure connection to the glass and distributing forces laterally to prevent peeling and cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrical terminal uses a conventional design with direct cable attachment, then the terminal can be easily assembled, but the terminal can be easily separated from the glass by peeling when pulling forces are exerted on the cable
Solution Approach 1:
The terminal is divided into distinct functional segments: a base portion for glass mounting, an intermediate portion for structural support, and a cable securing portion. This segmentation allows each part to perform its specific function optimally while maintaining overall reliability against peeling forces
Solution Approach 2:
The terminal structure extends in multiple dimensions with the base portion providing a broad footprint on the glass surface, the intermediate portion providing vertical support, and the cable securing portion extending outward. This multi-dimensional structure distributes pulling forces across different spatial planes, preventing peeling
2Reliability
If the electrical terminal has a large footprint for secure mounting, then the terminal resists peeling, but the terminal causes cracking of the glass during soldering due to heat related stress concentrations
Solution Approach 1:
The base portion is designed with a specific optimized footprint geometry that provides sufficient mounting surface area for reliable glass adhesion while avoiding excessive localized heat concentration during soldering. The shape and dimensions are tailored to achieve the right balance between mechanical attachment strength and thermal stress distribution
Solution Approach 2:
The terminal design converts the potential harm of heat concentration by distributing the thermal load across an optimized footprint that prevents stress concentration points, thereby preventing glass cracking while maintaining secure mounting
3Loss of substance
If the electrical terminal uses a compact design, then the terminal reduces material usage, but the terminal is more prone to peeling when pulling forces are exerted on the cable
Solution Approach 1:
The terminal incorporates flexible intermediate portions and bending sections that allow the structure to dynamically absorb and redistribute pulling forces. This dynamic flexibility enables a compact overall design while maintaining peeling resistance through force distribution along the terminal's length
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An electrical terminal (100) includes a base portion (102) having a base portion outer surface (104), a base portion inner surface (106), and two securing tabs (108) extending from an edge of the base portion (102). The electrical terminal (100) also an attachment portion (110) having an attachment portion outer surface (112) an attachment portion inner surface (114). The base portion inner surface (106) is proximate the attachment portion inner surface (114) and wherein the two securing tabs (108) overlay the attachment portion outer surface (112). The electrical terminal (100) may be especially well suited for making an electrical connection to components disposed on a glass surface. A method for forming such a terminal (100) is also presented.