Windscreen Connector with Encased Conductive Strip
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Solution Overview
Problem
Existing connectors for heated windscreens face challenges in withstanding environmental conditions like thermal cycling, humidity, and chemical exposure, and physical demands such as bending around small radii, while ensuring weatherproofing and accurate installation.
Innovation Solution
The development of a connector comprising a flat strip of electrically conductive material encased in non-conductive material with an adhesive layer, allowing for intermittent application of adhesive and cutting to form robust, environmentally resistant connectors capable of carrying high electrical loads and bending without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If connectors are made thin to allow bending around small radii, then ease of installation and physical resilience improve, but strength and ability to carry electrical loads deteriorate
Solution Approach 1:
The connector uses a composite structure combining a thin conductive strip (for flexibility and bending capability) with a non-conductive encasing material (for protection and structural integrity). This composite construction allows the connector to be thin enough to bend around small radii while maintaining sufficient strength to carry electrical loads for large windscreens.
2Reliability
If connectors are made robust to withstand environmental conditions, then reliability improves, but ease of installation and location deteriorate
Solution Approach 1:
The non-conductive encasing material acts as a flexible protective shell that shields the conductive strip from environmental conditions (thermal cycling, humidity, chemical exposure) while maintaining a thin profile that does not interfere with installation or accurate location on the windscreen.
3Reliability
If adhesive is applied to entire width of connector, then reliability of connection improves, but manufacturing complexity increases
Solution Approach 1:
Instead of applying adhesive to the entire width of the connector, the adhesive is applied only to a minor portion (local area) of the non-conductive material. This selective local application maintains sufficient connection reliability while simplifying the manufacturing process and reducing adhesive material usage.
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 provides connectors that are physically resilient, environmentally resistant, and easy to install, maintaining weatherproofing while supporting large windscreen heating loads and withstanding repeated bending and environmental tests without performance impairment.
Implementation Method 1
an adhesive layer which covers the entire width of the connector and is located at or towards one end of the non-conductive material
Implementation Method 2
the intermediate the first and second ends the conductive material is encased in a thin non-conductive material
Implementation Method 3
a flat strip of electrically conductive material having a first exposed end and a second end for providing electrical contacts
Data Source
Figure 1A~2
Figure 3
Figure 4~5
AI summary
A connector (1) for installation in a windscreen, the connector (1) comprises a flat strip of electrically conductive material (2) having a first end (1A) and a second end (1B) for providing electrical contacts, intermediate the first (1A) and second ends (1 B) the conductive material (2) is encased in a thin non-conductive material (3), the connector (1) further comprises an adhesive layer (4) located at or towards one end of the non-conductive material (3) and extending along a minor portion of the non-conductive material (3).