Detachable Wire Assembly for Electrochromic Window Replacement

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Solution Overview

Problem

Existing electrochromic window systems face challenges in efficiently delivering power to optically switchable panes during installation and handling, leading to potential damage of wiring components and high replacement costs due to permanent attachment of wire assemblies.

Innovation Solution

The implementation of detachable wire assemblies with magnetic connectors and onboard controllers, allowing for flexible installation, testing, and easy replacement of electrical components, while ensuring secure and reliable electrical communication.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If wire assemblies are permanently attached to electrochromic window systems, then electrical connection reliability is improved, but damage to wiring components increases and replacement costs rise

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidwiring component replacement

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The wire assembly is divided into separate modular components including a connector portion that attaches to the electrochromic device and a wire portion that extends to external controls. This segmentation allows individual components to be replaced independently without damaging other parts of the system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector is designed with flexible attachment mechanisms that provide secure electrical connection during normal operation but allow for controlled detachment when replacement is needed. The dynamic design enables the system to transition between stable operation and easy maintenance states.

Inventive Principle:

Principle #15Dynamics

2Reliability

If wire assemblies are permanently attached to electrochromic window systems, then electrical connection stability is improved, but manufacturing costs increase due to higher replacement costs

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By segmenting the wire assembly into replaceable modules, the manufacturing cost of individual components is reduced. When a component fails, only that specific module needs to be manufactured and replaced, rather than manufacturing an entirely new electrochromic window system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular design enables selective replacement of worn or damaged wire assembly components while retaining functional parts. This extends the overall system life and reduces total manufacturing costs by recovering and reusing viable components.

Inventive Principle:

Principle #34Discarding and recovering

3Ease of operation

If wire assemblies are permanently attached, then installation simplicity is improved, but flexibility in installation and handling decreases

Engineering Contradiction:

Improveinstallation simplicityVSAvoidinstallation flexibility

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The connector design provides dynamic attachment capabilities that simplify installation through straightforward connection mechanisms while maintaining the flexibility to be repositioned or reconnected if needed. The system transitions from a fixed permanent attachment to a controllable reversible attachment.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The connector acts as an intermediary component between the electrochromic device and external wiring. This intermediary provides a standardized interface that simplifies installation while enabling flexibility in routing and configuration options.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 approach reduces manufacturing costs and minimizes damage to electrochromic window systems by enabling modular and secure electrical connections, facilitating convenient installation and maintenance, and reducing the need for entire unit replacement.

Implementation Method 1

The second connector further includes a second ferromagnetic element, which itself may be magnetized. At least one of the first and second ferromagnetic elements is magnetized such that the first and second connectors may magnetically engage one another to provide electrical communication between their respective contacts.

Methodology Applied

Scientific EffectMagnetic engagement: Magnetism

Data Source

PatentEP3434853B1Detachable wire assembly and insulated glass unit with a such detachable wire assembly

Publication Date: 2025.10.22 VIEW INC

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AI summary

This disclosure provides connectors for smart windows. A smart window may incorporate an optically switchable pane. In one aspect, a window unit includes an insulated glass unit including an optically switchable pane. A wire assembly may be attached to the edge of the insulated glass unit and may include wires in electrical communication with electrodes of the optically switchable pane. A floating connector may be attached to a distal end of the wire assembly. The floating connector may include a flange and a nose, with two holes in the flange for affixing the floating connector to a first frame. The nose may include a terminal face that present two exposed contacts of opposite polarity. Pre-wired spacers improve fabrication efficiency and seal integrity of insulated glass units. Electrical connection systems include those embedded in the secondary seal of the insulated glass unit.