Compressive Edge Clip Connector for Plastic Window Terminals
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Solution Overview
Problem
Existing methods for attaching electrical terminals to plastic window systems with electrically conductive grids face issues such as loose connections due to fatigue and vibration, and inadequate bonding strength caused by low glass transition temperatures of plastics, which leads to unreliable defrosting and defogging capabilities in automotive windows.
Innovation Solution
A compressive edge clip connector system is used, where the edge clip biases the terminal into engagement with the conductive mounting location, and a bonding agent secures the clip to the panel, providing a robust connection that can withstand greater forces without damaging the plastic panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spring contacts are used to connect terminals to busbars, then electrical connection is achieved, but the connection becomes loose over time due to fatigue and vibration
Solution Approach 1:
The connection system is divided into separate functional components: a rigid mounting structure attached to the busbar, and a terminal portion that connects to it. This segmentation allows each part to be optimized independently - the mounting structure provides stable mechanical support while the terminal maintains electrical contact, eliminating the fatigue issues of spring contacts.
Solution Approach 2:
The patent replaces the mechanical spring contact system with a hybrid approach combining mechanical mounting (adhesive or mechanical attachment of mounting structure) with electrical connection. This substitution eliminates the reliance on spring tension and mechanical pressure maintenance, solving the loosening problem caused by vibration and fatigue.
2Strength
If traditional high temperature solder is used to attach terminals to bonding pads, then strong bonding is achieved, but the plastic panel is damaged due to high glass transition temperature
Solution Approach 1:
The attachment system is segmented into two distinct processes: (1) mechanical/adhesive attachment of the mounting structure to the busbar at low temperature, and (2) electrical connection of the terminal to the mounting structure. This segmentation allows the plastic panel to remain intact during the first stage while still achieving strong mechanical bonding, avoiding the need for high-temperature soldering that would damage the plastic.
Solution Approach 2:
The mounting structure serves as an intermediary component between the busbar and the terminal. It provides a mechanical attachment point that can be bonded at low temperatures (using adhesives or mechanical fasteners) and then electrically connected to the terminal, eliminating the need for direct high-temperature soldering to the plastic panel.
3Temperature
If low temperature solder or electrically conductive adhesives are used to attach terminals to busbars, then plastic panel is protected from damage, but bonding strength is insufficient and terminals can be easily dislodged
Solution Approach 1:
The connection system uses composite construction combining different materials and attachment methods: the mounting structure (made of conductive material) is mechanically or adhesively attached to the busbar, while the terminal is electrically connected to the mounting structure. This composite approach achieves both low-temperature processing (protecting the plastic) and high bonding strength (preventing terminal dislodgement).
Solution Approach 2:
The patent replaces weak adhesive or solder bonds with a mechanical mounting structure that provides robust physical attachment. The mounting structure is securely attached to the busbar through mechanical means (such as snap-fit, mechanical fasteners, or structural adhesive) rather than relying on weak conductive adhesives, thereby achieving the required 30-pound force resistance while maintaining low-temperature processing.
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 ensures reliable and durable attachment of electrical terminals to the conductive grids, enhancing the performance and longevity of defrosting and defogging systems by maintaining electrical contact under varying forces and environmental conditions.
Implementation Method 1
a bonding agent secures the clip to the panel
Implementation Method 2
the edge clip biases the terminal into engagement with the conductive mounting location
Implementation Method 3
During the passing of electric current through the heating grid, the resistance of the grid lines results in the generation of heat
Data Source
AI summary
A plastic window system including a transparent plastic panel and an electrically conductive grid provided on the plastic panel. The conductive grid includes at least one conductive mounting location. An electrical terminal is electrically connected to the conductive mounting location, and a connector secures the terminal to the conductive mounting location. The connector includes a portion extending from the panel to a location outboard of the conductive mounting location relative to the panel.