Strain-resistant electrical connection

• US 20050230148A1
• Filed: 04/19/2004
• Published: 10/20/2005
• Est. Priority Date: 04/19/2004
• Status: Active Grant

• Current Assignee: Michelin Recherche et Technique SA (Compagnie Generale DES Etablissements Michelin SCA)
• Original Assignee: Michelin Recherche et Technique SA (Compagnie Generale DES Etablissements Michelin SCA)
• Inventors: Sinnett, Jay C., Metcalf, Arthur R.
• Granted Patent: US 7,674,117 B2
• Time in Patent Office: Days
• US Class Current: 174/267
• CPC Class Codes: B29D 2030/0072 Attaching fasteners to tyres, e.g. patches, in order to connect devices to tyres
• CPC Class Codes: B29D 2030/0083 Attaching monitoring devices to tyres before or after vulcanization by inserting them inside tyre cavities
• CPC Class Codes: B60C 23/0452 Antenna structure, control or arrangement vehicle tyre mounted antennas H01Q1/2241
• CPC Class Codes: B60C 23/0493 for attachment on the tyre
• CPC Class Codes: H01R 13/58 Means for relieving strain on wire connection, e.g. cord grip , for avoiding loosening of connections between wires and terminals within a coupling device terminating a cable for flat or ribbon cables H01R12/771
• CPC Class Codes: H01R 13/5808 formed by a metallic element crimped around the cable H01R4/185 takes precedence
• CPC Class Codes: H01R 13/5845 the strain relief being achieved by molding parts around cable and connections
• CPC Class Codes: H01R 2201/02 for antennas
• CPC Class Codes: H01R 2201/26 for vehicles
• CPC Class Codes: H01R 4/02 Soldered or welded connections H01R4/625, H01R4/723, H01R12/59 take precedence
• CPC Class Codes: H01R 4/20 using a crimping sleeve H01R4/01 takes precedence
• CPC Class Codes: H01R 43/0256 for soldering or welding connectors to a printed circuit board
• CPC Class Codes: H05K 2201/0133 Elastomeric or compliant polymer elastomeric conductor H05K2201/0314
• CPC Class Codes: H05K 2201/10265 Metallic coils or springs, e.g. as part of a connection element
• CPC Class Codes: H05K 2201/10287 Metal wires as connectors or conductors
• CPC Class Codes: H05K 2203/1194 Thermal treatment leading to a different chemical state of a material, e.g. annealing for stress-relief, aging
• CPC Class Codes: H05K 3/301 by means of a mounting structure H05K3/325 takes precedence
• CPC Class Codes: H05K 3/305 Affixing by adhesive
• CPC Class Codes: H05K 3/3421 Leaded components
• CPC Class Codes: Y10S 439/947 PCB mounted connector with ground terminal

Abstract

A strain-resistant electrical connection and a method of making the same is provided. A wire or other conductive lead is connected to a circuit in a manner that makes the connection more resistant to mechanical stresses such as movement or rotation of the lead relative to the circuit. A material is configured around the lead and near the point of connection to the circuit so as to create a region of decreasing flexibility or graduated stiffness near the point of connection. In certain embodiments, the lead may also be coiled or otherwise shaped to provide additional ability to withstand mechanical stresses.

Claims

1. A method of creating a fatigue-resistant electrical connection, comprising:

providing an electrical conductor having at least one end configured for connecting to an electrical circuit;

positioning a predetermined length of said electrical conductor proximate to said at least one end within a distributor, said distributor being configured for distributing stress over said predetermined length of said electrical conductor;

attaching said distributor to a support surface that is stationary relative to said electrical circuit; and

connecting said at least one end of said electrical conductor to the electrical circuit.

2. A method of creating a fatigue-resistant electrical connection as in claim 1, further comprising the step of adhering said electrical conductor to said distributor along said predetermined length.

3. A method of creating a fatigue-resistant electrical connection as in claim 1, wherein said distributor is comprised of a resilient material.

4. A method of creating a fatigue-resistant electrical connection as in claim 3, wherein said resilient material is comprised of rubber.

5. A method of creating a fatigue-resistant electrical connection as in claim 1, wherein said support surface comprises a printed circuit board.

6. A method of creating a fatigue-resistant electrical connection as in claim 5, wherein said step of attaching said distributor comprises gluing said distributor to said printed circuit board.

7. A method of creating a fatigue-resistant electrical connection as in claim 1, wherein said step of connecting said end of said electrical conductor comprises soldering said electrical conductor to said electrical circuit.

8. A method of creating a fatigue-resistant electrical connection as in claim 1, wherein said electrical conductor comprises a coiled wire.

9. A method of creating a fatigue-resistant electrical connection as in claim 8, wherein a non-conductive coating is applied to at least a portion of said coiled wire along said predetermined length.

10. A method of creating a strain-resistant electrical connection to an electrical circuit, comprising:

providing a resilient material capable of distributing mechanical forces;

positioning a portion of an electrical conductor proximate to a first of said conductor within said resilient material;

attaching said resilient material to a support; and

connecting said first end of said electrical conductor to the electrical circuit in a manner that fixes the position of said first end relative to said support, whereby said resilient material provides a transition zone in said resilient material for said electrical conductor in which the flexibility of said electrical conductor decreases along a direction from the point of entry of said conductor into said resilient material towards the point of connection of said first end to said electrical circuit.

11. A method of creating a strain-resistant electrical connection as in claim 10, further comprising the step of adhering said electrical conductor to said resilient material.

12. A method of creating a strain-resistant electrical connection as in claim 10, wherein said connecting step comprises crimping a conductive connector through said resilient material and into contact with said electrical conductor.

13. A method of creating a strain-resistant electrical connection as in claim 10, wherein said electrical conductor further comprises a coiled wire.

14. A method of creating a strain-resistant electrical connection as in claim 13, wherein said coiled wire further comprises steel coated with brass.

15. A method of creating a strain-resistant electrical connection as in claim 10, wherein said resilient material is rubber.

16. A method of creating a strain-resistant electrical connection as in claim 10, wherein at least a portion of said electrical circuit is located upon said support.

17. A durable connection for an electrical circuit, comprising:

a substrate supporting at least a portion of said electrical circuit;

a conductor having at least one connecting end attached to said electrical circuit; and

a resilient material positioned proximate said connecting end and surrounding a predetermined portion of said conductor, said resilient material attached to said substrate and configured for gradually restricting the mobility of said conductor along said end in a direction moving along said conductor and towards said electrical circuit.

18. A durable connection for an electrical circuit as in claim 17, wherein said resilient material is adhered to at least a portion of said conductor.

19. A durable connection for an electrical circuit as in claim 18, wherein said conductor comprises a coiled wire.

20. A durable connection for an electrical circuit as in claim 19, wherein said substrate comprises a printed circuit board that includes at least a portion of said electrical circuit.

21. A durable connection for an electrical circuit as in claim 20, wherein said resilient material is comprised of an elastomer.

22. A strain-resistant electrical connection to an electrical circuit, comprising:

a material for distributing stress;

a wire having a first end, wherein a portion of said wire near said first end is embedded within said material for distributing stress;

a wire-connector in electrical communication with said circuit, said wire connector enclosing at least a portion of said stress distributing material and physically contacting and restraining said wire proximate to said first end so as provide an electrical connection; and

a support surface that is substantially immovable relative to said circuit, said material for distributing stress being attached to said support surface;

wherein said material for distributing stress is configured to provide a zone of graduated stiffness about said wire proximate to said first end.

23. A strain-resistant electrical connection for an electrical circuit as in claim 22, wherein said material for distributing stress is comprised of rubber.

24. A strain-resistant electrical connection for an electrical circuit as in claim 23, wherein said wire comprises a coiled spring connector constructed from a brass-coated steel.

25. A strain-resistant electrical connection for an electrical circuit as in claim 22, wherein said wire is bonded to said material for distributing stress.

26. A strain-resistant electrical connection for an electrical circuit as in claim 22, further comprising a non-conductive coating located upon said wire so as to insulate said wire from said material for distributing stress.

27. A strain-resistant electrical connection for an electrical circuit as in claim 26, wherein said non-conductive coating is bonded to said material for distributing stress.