Window Electrical Terminals Using Adhesive Bonding and Conformal Coating
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Solution Overview
Problem
Existing methods for providing electrical power to vehicle windows with integrated electrical elements are inefficient and prone to environmental damage, often requiring leaded solders that can cause glass cracking and are costly to manufacture.
Innovation Solution
A vehicle window system featuring an electrical bus on the interior surface with an electrical terminal and connector, secured by adhesives and protected by a conformal coating, eliminates the need for leaded solders and enhances retention at high temperatures, using a spring tab for robust connections and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If leaded solders are used to provide electrical connections, then electrical power can be supplied to window elements, but glass cracking occurs and manufacturing costs increase
Solution Approach 1:
The patent removes leaded solders from the electrical connection system entirely, extracting the harmful element while maintaining electrical functionality through alternative means (adhesive bonding with conductive properties)
Solution Approach 2:
The invention uses cost-effective adhesive materials instead of expensive leaded solders, reducing manufacturing costs while providing sufficient electrical connection for the application lifecycle
2Reliability
If leaded solders are used to provide electrical connections, then electrical power can be supplied to window elements, but manufacturing costs increase
Solution Approach 1:
The patent substitutes expensive leaded solders with more economical adhesive materials that provide adequate electrical connection, directly reducing manufacturing costs
3Temperature
If adhesive is used to secure connector to bus, then retention at high temperatures is enhanced, but electrical conductivity may be compromised
Solution Approach 1:
The patent employs adhesive materials with composite properties that simultaneously provide both mechanical bonding strength for high temperature retention and electrical conductivity for reliable power transmission
4Object-affected harmful factors
If conformal coating is applied over connector and adhesive, then environmental protection is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses conformal coating as a thin protective film that shields the connector and adhesive from environmental damage while adding minimal complexity to the manufacturing process
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 solution provides a reliable, cost-effective, and environmentally friendly method for powering vehicle windows, reducing the risk of glass cracking and simplifying manufacturing, while ensuring secure and durable electrical connections.
Implementation Method 1
An adhesive is positioned between the connector and the electrical bus
Implementation Method 2
A conformal coating is positioned over the connector and the adhesive
Implementation Method 3
An electrical terminal is positioned on the bus. A connector is electrically coupled with the bus
Data Source
AI summary
A vehicle includes a window defining an exterior surface and an interior surface. An electrical bus is positioned on the interior surface. An electrical component is positioned on the window and electrically coupled with the bus. An electrical terminal is positioned on the bus. A connector is electrically coupled with the bus. An adhesive is positioned between the connector and the electrical bus. A conformal coating is positioned over the connector and the adhesive.