Circular Foot Electrical Connector for Glazing
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Solution Overview
Problem
Conventional electrical connectors used in vehicle glazing with lead-free solder suffer from mechanical instability and increased glass breakage due to thermal cycling, leading to unreliable connections and environmental concerns from lead contamination.
Innovation Solution
An electrical connector design featuring a substantially circular foot permanently connected to an angled portion, utilizing lead-free solder to enhance adhesion and reduce glass breakages, with a holding portion like a ledge or washer for secure cable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If lead-free solder is used instead of conventional lead-containing solder, then environmental safety and health concerns are reduced, but mechanical strength and reliability of the solder joint deteriorate
Solution Approach 1:
The patent changes the geometric parameters of the connector components, specifically optimizing the height of the connector bridge (h) and the protrusions (d) to improve mechanical strength and reliability when using lead-free solder
Solution Approach 2:
The patent combines lead-free solder with specifically designed geometric features of the connector (bridge and protrusions) to create a composite system that achieves both environmental safety and mechanical reliability
2Object-affected harmful factors
If lead-free solder is used instead of conventional lead-containing solder, then environmental safety is improved, but mechanical stability and resistance to thermal cycling deteriorate
Solution Approach 1:
The patent optimizes geometric parameters (bridge height h and protrusion height d) to enhance mechanical stability and resistance to thermal cycling when using lead-free solder
Solution Approach 2:
The patent specifies that the protrusions should have a radius of curvature between 0.1mm and 0.5mm, using curved surfaces to improve stress distribution and mechanical stability under thermal cycling conditions
3Ease of manufacture
If conventional T-piece with rectangular feet is used, then manufacturing simplicity is maintained, but glass breakage in the region of solder increases
Solution Approach 1:
The patent replaces rectangular feet with protrusions that have a radius of curvature between 0.1mm and 0.5mm, reducing stress concentration points and thereby reducing glass breakage
Solution Approach 2:
The patent changes the geometric parameters including the curved shape of protrusions and the height of the connector bridge to reduce stress on the glass and prevent breakage
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 connector design significantly reduces glass breakages and improves adhesion with lead-free solder, ensuring durability and reliability under thermal cycling conditions, while avoiding lead-related environmental issues.
Implementation Method 1
connecting the foot to an electrical conductor on a sheet of glazing material by means of a layer of lead-free solder
Data Source
Figure 1~2
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AI summary
An electrical connector used to make electrical connection to a heating system or to an antenna system ona glazing, and a method of manufacturing a glazing, are disclosed. The electrical connector (30) comprises a substantially planar foot (31),suitable for soldering, an angled portion (32), permanently connected to the foot (31) and substantially at right angles to the plane of the foot (31)and a holding portion (33), connected to the angled portion (32) and suitable for holding a cable, wherein the foot (31) has a substantially circularor ovalshape.A glazing (10) comprising such an electrical connector (30) further comprises a sheet of glazing material (11), an electrical conductor (21) on a surface of the sheet of glazing material (11)anda solder layer (41) between the electrical conductor (21) and the foot (31)wherein the solder layer (41) comprises lead-free solder. The angled portion may be a male portion of a button connector, also known as a snap connector. The holding portion may be a washer soldered or welded to the angled portion.