Electrical Terminal Surface Texturing for Potting Adhesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical terminals in vehicle systems face issues with adhesion to potting materials, leading to water ingress and connector failure, which is costly due to inadequate surface treatment and engagement features.
Innovation Solution
The electrical terminal features a non-uniform outer surface with engagement features formed using extended dual laser interference patterning (xDLIP), enhancing adhesion to both the header and potting material, and incorporating plasma surface treatment for cleanliness and hydrophilicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional smooth surface treatment is used on electrical terminals, then manufacturing is simple, but adhesion to potting material is insufficient leading to water ingress and failure
Solution Approach 1:
The patent applies local quality by creating engagement features (protrusions and recesses) at specific locations on the electrical terminal surface where adhesion is needed, rather than uniformly treating the entire surface. This localized approach improves adhesion to potting material at critical interfaces while keeping the rest of the terminal structure simple and manufacturable.
Solution Approach 2:
The engagement features are formed on the electrical terminal surface before the potting material is applied. This preliminary surface preparation ensures that when the potting material is later applied, it immediately bonds to the pre-formed engagement features, preventing water ingress and ensuring reliable adhesion from the outset.
2Reliability
If engagement features are added to improve adhesion, then connection reliability improves, but manufacturing complexity increases
Solution Approach 1:
The patent replaces traditional mechanical surface treatment methods (such as machining, stamping, or forming engagement features) with a laser-based surface treatment process. This substitution enables precise creation of engagement features without complex tooling or multiple manufacturing steps, improving connection reliability while maintaining ease of manufacture through a streamlined laser processing approach.
3Object-affected harmful factors
If surface treatment is applied to enhance adhesion, then water ingress resistance improves, but production time increases
Solution Approach 1:
The laser surface treatment process operates in periodic pulses, creating engagement features through controlled, repeated laser pulses rather than continuous processing. This periodic action allows for precise feature formation while maintaining high production speeds, as the laser can quickly move between pulses and the process is highly automated, thereby improving water ingress resistance without significantly impacting productivity.
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 improves adhesion and sealing, reducing the risk of water ingress and connector failure, while maintaining robustness under thermal conditions, thus minimizing scrap rates and ensuring reliable electrical connections.
Implementation Method 1
forming a plurality of engagement features on an outer surface of the electrical terminal with an extended dual laser interference patterning (xDLIP) process
Implementation Method 2
incorporating plasma surface treatment for cleanliness and hydrophilicity
Data Source
AI summary
An electrical terminal assembly for a vehicle electrical connector assembly includes a header. The electrical terminal assembly also includes a potting material disposed within a cavity of the header. The electrical terminal assembly further includes an electrical terminal extending through the header and the potting material, the electrical terminal formed of metal and having a non-uniform outer surface including at least one engagement feature for adhering to the header and the potting material.