Vent Integrated Terminal Aperture for Circuit Pressure Relief
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Solution Overview
Problem
Trapped gases under sealants in circuit assemblies can generate pressure against the circuitry, leading to reliability issues and manufacturing challenges, especially in automotive sensing units, where traditional methods of relieving pressure are cumbersome and inefficient.
Innovation Solution
Incorporating vent holes with a larger cross-sectional profile into terminal holes allows gases to escape, improving reliability and manufacturing ease by forming passages between the circuit cavity and the connector recess, and enabling pressure relief and testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the housing is sealed with sealant to protect the circuit from contamination, then the reliability of the circuit is improved, but trapped gases generate pressure against the circuitry causing reliability issues
Solution Approach 1:
The terminal opening is designed with a cross-sectional profile larger than the terminal itself, creating an annular passage that functions as a porous pathway. This allows trapped gases to escape while the sealant maintains the protective seal around the terminal, resolving the contradiction between sealing and pressure relief.
Solution Approach 2:
The annular passage formed by the larger terminal opening acts as an intermediary pathway between the sealed cavity and the external environment. It mediates the escape of trapped gases without compromising the sealant's protective function, allowing pressure relief while maintaining circuit protection.
2Object-generated harmful factors
If separate vent holes are added to relieve trapped gases, then pressure relief is achieved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The venting function is merged with the existing terminal opening structure. By making the terminal opening larger than the terminal cross-section, the same structural element serves both electrical connection and pressure relief functions, eliminating the need for separate vent holes and reducing overall device complexity.
Solution Approach 2:
The terminal opening is designed to serve multiple functions: providing electrical connection for the terminal and simultaneously acting as a vent passage for trapped gases. This multi-functionality reduces the number of components needed and simplifies the housing structure.
3Object-generated harmful factors
If the terminal opening cross-sectional profile is made larger than the terminal, then gas escape passages are formed, but the manufacturing precision requirements increase
Solution Approach 1:
The terminal opening is segmented into two functional zones: a larger outer profile that provides the vent passage and a smaller inner region that accommodates the terminal. This segmentation allows each zone to be optimized independently, with the annular passage providing adequate venting without requiring extremely tight tolerances on the entire opening.
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
This design effectively evacuates trapped gases, enhances the reliability of circuit assemblies, and simplifies the manufacturing process by eliminating the need for separate pressure relief mechanisms, while also allowing for testing purposes.
Implementation Method 1
One or more of the openings may a cross sectional profile larger than a cross sectional profile of the terminal such that a passage is formed between the cavity and the recess after the terminal is inserted through the opening. This passage may allow trapped gasses or liquids to escape the cavity where the circuit is located or allow for pressure to be applied for testing.
Data Source
AI summary
A circuit assembly for mounting on a vehicle assembly is provided. The circuit assembly may be a mountable sensor assembly. The assembly may include a housing with a cavity that houses a circuit, for example a sensor circuit. The circuit may be sealed in the cavity of the housing by epoxy. The housing may include a connector recess with terminals extending into the connector recess. The terminals may provide an electrical connection to the circuit. The housing may have openings between the cavity and the connector recess through which the terminals extend. One or more of the openings may have a cross sectional profile larger than the cross sectional profile of the terminal such that a passage is formed between the cavity and the recess after the terminal is inserted through the opening.