Window Electrical Connection Enclosure for Fluid-Tight Joint Sealing
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Solution Overview
Problem
Window assemblies with electrical connections face issues of mechanical stress and water ingress, leading to corrosion and failure of electrical joints, particularly due to differences in thermal expansion coefficients and the inability of direct polymeric encapsulants to effectively seal the joints.
Innovation Solution
A fluidically-sealed enclosure assembly is provided, comprising a transparent pane with an electrical conductor and a wiring harness, where a mechanically protective enclosure is adhered to the pane, creating a fluid-tight seal around the electrical joint to prevent water ingress and reduce mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If direct polymeric encapsulation is applied to cover the solder joint, then the solder joint is protected from direct exposure to elements, but water penetrates through the encapsulant and contacts the electrical conductor near the solder joint, causing corrosion
Solution Approach 1:
The enclosure assembly is divided into multiple components: a first enclosure portion adhered to the transparent pane, a second enclosure portion, and a sealing member positioned between them. This segmentation creates a more effective barrier system compared to direct encapsulation, as each component performs a specific protective function and the sealing member specifically addresses water ingress at the interface.
Solution Approach 2:
A sealing member is introduced as an intermediary element between the first and second enclosure portions. This sealing member specifically prevents water penetration at the interface where water would most likely ingress, thereby protecting the electrical conductor and solder joint from corrosion while maintaining the overall enclosure structure.
2Reliability
If polymeric encapsulation is applied directly to the solder joint, then the joint is covered, but differences in coefficients of thermal expansion create mechanical stress that can crack the glass pane or delaminate the electrical conductor
Solution Approach 1:
The enclosure assembly separates the protective function from the thermal expansion issue by not directly encapsulating the solder joint with polymeric material. Instead, the enclosure portions and sealing member create a protective barrier without directly bonding to the solder joint, thereby eliminating the thermal expansion stress that would occur with direct polymeric encapsulation.
Solution Approach 2:
The sealing member acts as an intermediary that provides sealing without direct thermal expansion compatibility requirements with the solder joint. By positioning the sealing member between enclosure portions rather than directly on the joint, the system avoids the mechanical stress problem while still achieving protection.
3Device complexity
If the electrical joint is exposed to elements, then the assembly structure is simple, but the solder joint corrodes and weakens due to exposure
Solution Approach 1:
The enclosure assembly uses multiple components (first enclosure portion, second enclosure portion, sealing member) to provide comprehensive protection. This segmented approach creates effective protection against corrosion while maintaining reasonable structural simplicity, as each component has a defined function and can be manufactured and assembled using standard processes.
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 effectively reduces mechanical stress and prevents water-catalyzed corrosion of the electrical joint, enhancing the longevity and reliability of the window assembly by creating a robust environmental barrier.
Implementation Method 1
The transparent-pane engaging surface is adhered to the transparent pane
Implementation Method 2
The first interface surface engages the second interface surface to provide a first fluid-tight seal
Implementation Method 3
The opening engages the wiring harness to provide a second fluid-tight seal therebetween
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Systems and methods for environmentally sealing electrical connections of window assemblies are disclosed. A mechanically protective enclosure assembly is adhered to a transparent pane including glass. The enclosure assembly includes a first member, a second member, and an opening. The first member includes a transparent-pane engaging surface, a first interface surface, and a plurality of first walls extending therebetween. The second member is attached to the first member. The second member includes a top member, a second interface surface, and a plurality of second walls extending therebetween. The first interface surface engages the second interface surface to provide a first fluid-tight seal. The opening is defined by at least one of the plurality of first walls and at least one of the plurality of second walls. The opening engages the wiring harness to provide a second fluid-tight seal therebetween.