Graduated stiffness for electrical connections in tires

• US 20050231343A1
• Filed: 09/02/2004
• Published: 10/20/2005
• Est. Priority Date: 04/19/2004
• Status: Active Grant

• Current Assignee: Michelin North America Incorporated (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., Myatt, David J.
• Granted Patent: US 7,196,617 B2
• Time in Patent Office: Days
• US Class Current: 340/442
• CPC Class Codes: B29D 2030/0072 Attaching fasteners to tyres, e.g. patches, in order to connect devices to tyres
• CPC Class Codes: B60C 23/0493 for attachment on the tyre
• CPC Class Codes: H01Q 1/2241 used in or for vehicle tyres
• CPC Class Codes: H01Q 1/40 Radiating elements coated with or embedded in protective material
• CPC Class Codes: H01R 12/53 connecting to cables except for flat or ribbon cables
• 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

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. In other embodiments, additional elements may be provided to assist in controlling the stiffness near the connection point.

Claims

1. A method of creating a fatigue-resistant electrical connection in a tire patch, comprising the steps of:

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

providing an electrical circuit including at least one connection point;

connecting said at least one end of said electrical conductor to the at least one connection point; and

encasing said electrical conductor and said electrical circuit in a stress reducing material so as to provide a transition zone wherein strain applied to the electrical conductor varies as a function of distance from the at least one connection point,

whereby the stress reducing material distributes strain applied to the electrical conductor and forms a tire patch.

2. A method as in claim 1, further comprising the step of bonding said stress reducing material to said electrical conductor.

3. A method as in claim 1, wherein said stress reducing material is comprised of a resilient material.

4. A method as in claim 3, wherein said resilient material is comprised of rubber.

5. A method as in claim 4, where a portion of the rubber comprises a portion of a tire body.

6. A method as in claim 1, wherein said electrical circuit comprises a printed circuit board.

7. A method as in claim 6, wherein said step of encasing comprises bonding said strain distributing material to said printed circuit board.

8. A method as in claim 1, wherein said step of connecting comprises soldering said electrical conductor to said electrical connection point.

9. A method as in claim 1, wherein said electrical conductor comprises a coiled wire.

10. A method as in claim 9, wherein a non-conductive coating is applied to at least a portion of said electrical conductor along a predetermined length.

11. A method of creating a strain-resistant electrical connection to an electrical circuit in a tire patch, comprising:

providing a resilient material capable of distributing mechanical forces;

providing an electrical circuit mounted on a support, the electrical circuit having at least one connection point;

positioning an electrical conductor proximate to said at least one connection point, said electrical conductor having a first end and a second end;

connecting said first end of said electrical conductor to said connection point of the electrical circuit in a manner that fixes the position of said first end relative to said support; and

attaching said resilient material to said support and said electrical conductor,

whereby said resilient material provides a transition zone for said electrical conductor such that the mobility of said electrical conductor decreases along a direction from said second end of said electrical conductor towards said point of connection of said first end to the electrical circuit.

12. A method as in claim 11, further comprising the step of adhering said electrical conductor to said resilient material.

13. A method as in claim 11, wherein said electrical conductor further comprises a coiled wire.

14. A method as in claim 13, wherein said coiled wire further comprises steel coated with brass.

15. A method as in claim 11, wherein said resilient material is rubber.

16. A method as in claim 15, wherein a portion of the rubber comprises a portion of a tire.

17. A method as in claim 11, wherein at least a portion of said electrical circuit is located upon said support.

18. A durable connection for an electrical circuit in a tire patch, comprising:

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

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

a resilient material positioned proximate said connecting portion and surrounding 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 and forming a tire patch.

19. A durable connection as in claim 18, wherein said resilient material is adhered to at least a portion of said conductor.

20. A durable connection as in claim 19, wherein said conductor comprises a coiled wire.

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

22. A durable connection as in claim 21, wherein said resilient material is comprised of an elastomer.

23. A durable connection as in claim 20, wherein the coils of said conductor comprise a plurality of pitches along the length of the conductor and wherein the coil pitch proximate said connecting portion is higher than the coil pitch more distant from the connecting portion.

24. A durable connection as in claim 18, further comprising:

a second conductor having at least one portion co-attached to said electrical circuit with the connecting portion of the first named conductor, said second conductor attached to said resilient material,

whereby said second conductor cooperates with the resilient material to restrict the mobility of said first named conductor.

25. A durable connection as in claim 24, wherein said second conductor comprises a wire of predetermined length and wherein said second conductor is co-attached to said electrical circuit at a mid portion of said second conductor.

26. A durable connection as in claim 24, wherein said second conductor comprises a portion of the first named conductor from the connection portion thereof to an end portion thereof and wherein the second conductor is positioned in a plane substantially parallel to the direction said first named conductor.

27. A durable connection as in claim 26, wherein said first named conductor comprises a coiled wire and a portion of said second conductor is positioned within the coils of said first named conductor proximate said connection portion.

28. A durable connection as in claim 24, wherein said second conductor comprises a protrusion attached to said printed circuit board.

29. A durable connection as in claim 28, wherein said first named conductor is a coiled wire and wherein the coils of said first named conductor are positioned to substantially surround said protrusion.

30. A tire patch comprising:

an electrical circuit comprising at least one electrical component;

an electrical conductor having a predetermined length and including a connection portion connected to said at least one electrical component; and

a strain distributing material encasing said electrical circuit and said electrical conductor,

whereby the strain distributing material distributes any strain applied to the electrical conductor and connection to reduce strain induced damage to the electrical conductor and connection and forms the tire patch.

31. A tire patch as in claim 30, wherein said electrical conductor comprises a coiled wire.

32. A tire patch as in claim 30, wherein said strain distributing material is adhered to said electrical conductor and said electrical circuit.

33. A tire patch as in claim 31, wherein the coils of said coiled wire comprise a plurality of pitches along the length of the conductor and wherein the coil pitch proximate said connection portion is higher than the coil pitch more distant from the connection portion.

34. A tire patch as in claim 30, further comprising:

a second conductor having at least one portion co-attached to said electrical circuit with the connecting portion of the first named conductor, said second conductor adhered to said strain distributing material,

whereby said second conductor cooperates with the strain distributing material to restrict the mobility of said first named conductor.

35. A tire patch as in claim 34, wherein said second conductor comprises a wire of predetermined length and wherein said second conductor is co-attached to said electrical circuit at a mid portion of said second conductor.

36. A tire patch as in claim 34, wherein said second conductor comprises a portion of the first named conductor from the connection portion thereof to an end portion thereof and wherein the second conductor is positioned in a plane substantially parallel to the direction said first named conductor.

37. A tire patch as in claim 36, wherein said first named conductor comprises a coiled wire and a portion of said second conductor is positioned within the coils of said first named conductor proximate said connection portion.

38. A tire patch as in claim 34, wherein said second conductor comprises a protrusion attached to said electrical circuit.

39. A tire patch as in claim 38, wherein said first named conductor is a coiled wire and wherein the coils of said first named conductor are positioned to substantially surround said protrusion.

40. A method for providing a durable electrical connection, comprising:

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

providing an electrical circuit;

connecting said at least one portion of said electrical conductor to the electrical circuit; and

encasing said electrical conductor and said electrical circuit in a strain distributing material,

whereby the strain distributing material distributes any strain applied to the electrical conductor and connection to reduce strain induced damage to the electrical conductor and connection.

41. A method as in claim 40, further comprising the step of bonding said strain distributing material to said electrical conductor.

42. A method as in claim 40, wherein said strain distributing material comprise a resilient material.

43. A method as in claim 42, wherein said resilient material is comprised of rubber.

44. A method as in claim 43, where a portion of the rubber comprises a portion of a tire body.

45. A method as in claim 40, wherein said electrical circuit comprises a printed circuit board.

46. A method as in claim 45, wherein said step of encasing comprises bonding said strain distributing material to said printed circuit board.

47. A method as in claim 40, wherein said step of connecting said portion of said electrical conductor comprises soldering said electrical conductor to said electrical circuit.

48. A method as in claim 40, wherein said electrical conductor comprises a coiled wire.

49. A method as in claim 48, wherein a non-conductive coating is applied to at least a portion of said electrical conductor along a predetermined length.

50. A method as in claim 48, wherein the coils of said conductor are formed with a plurality of pitches along the length of the conductor and wherein the coil pitch proximate the connection is higher than the coil pitch more distant from the connection.