Prefabricated Conductor Carrier for Electrochromic Glazing
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Solution Overview
Problem
Current methods for manufacturing laminated glazing elements with electrically controllable light transmission properties are time-consuming, costly, and result in low robustness due to manual processes and prone to contact failures.
Innovation Solution
A composite pane element design where a prefabricated conductor carrier contacts both surface electrodes of each functional zone simultaneously, reducing the need for individual edge contacts and enhancing robustness by arranging contact elements in pairs to facilitate easier and more reproducible production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual processes (copper adhesive tape, soldering copper tabs and wires) are used to contact functional zones, then individual contact can be achieved, but the manufacturing process becomes time-consuming, expensive, and poorly reproducible
Solution Approach 1:
Multiple contact elements for different functional zones are merged into a single prefabricated conductor carrier. This carrier simultaneously contacts multiple surface electrodes during one manufacturing step, replacing the previous sequential manual process of applying individual copper tabs and soldering wires for each functional zone, thereby dramatically improving both productivity and manufacturing consistency
Solution Approach 2:
The conductor carrier is prefabricated in advance with all necessary contact elements and conductor elements already positioned and connected. This preliminary preparation allows the carrier to be applied as a complete assembly during manufacturing, eliminating the need for time-consuming on-site operations like manual soldering and significantly speeding up the production process
2Reliability
If manual soldering processes are used for each functional zone, then contact connections can be established, but the process becomes expensive and poorly reproducible
Solution Approach 1:
Multiple contact elements for different functional zones are merged into a single prefabricated conductor carrier. This carrier simultaneously contacts multiple surface electrodes during one manufacturing step, replacing the previous sequential manual process of applying individual copper tabs and soldering wires for each functional zone, thereby dramatically improving both productivity and manufacturing consistency
Solution Approach 2:
The conductor carrier is designed to be self-contained with all necessary electrical connections pre-established between contact elements and conductor elements. This self-service design eliminates the need for complex manual soldering operations during assembly, reducing manufacturing complexity while maintaining reliable electrical connections through the pre-fabricated structure
3Productivity
If contact tabs are applied manually to each functional zone, then individual contact is achieved, but the contact tabs tend to detach resulting in low robustness
Solution Approach 1:
Multiple contact elements for different functional zones are merged into a single prefabricated conductor carrier. This carrier simultaneously contacts multiple surface electrodes during one manufacturing step, replacing the previous sequential manual process of applying individual copper tabs and soldering wires for each functional zone, thereby dramatically improving both productivity and manufacturing consistency
Solution Approach 2:
The conductor carrier employs a flexible, curved design that allows it to conform to the edges of the functional element and maintain continuous contact pressure. This curved configuration distributes mechanical stress along the entire contact length rather than at discrete tab points, preventing detachment and significantly improving contact robustness
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 simplifies and automates the production process, increasing the robustness and reproducibility of composite pane elements with electrically controllable light transmission properties, allowing for mass production and improved durability.
Implementation Method 1
a functional element arranged in the space, comprising at least two functional zones, the light transmission properties of which can be changed independently of one another, at least partially, by applying an electrical voltage to two spaced-apart surface electrodes of the respective functional zone
Implementation Method 2
a conductor carrier for contacting the contact points of the surface electrodes, wherein the conductor carrier comprises a plurality of contact elements and a conductor element associated with each contact element
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a composite disc element (1) with electrically controllable light transmission properties, comprising a first disc element (2) and a second disc element (3), wherein a space (6) is located between the first disc element (2) and the second disc element (3); a functional element (4) arranged in the space (6), comprising at least two functional zones (7, 7', 7", 7‴), the light transmission properties of which can be changed independently of one another, at least partially, by applying an electrical voltage to two spaced-apart surface electrodes (7.21, 7.22) of the respective functional zone (7, 7', 7", 7‴), wherein each surface electrode (7.21, 7.22) comprises an associated contact point (8); and a conductor carrier (5) for contacting the contact points (8) of the surface electrodes (7.21, 7.22).22) comprising, wherein the conductor carrier (5) comprises a plurality of contact elements (12) and a conductor element (13) associated with each contact element (12), wherein the composite disk element (1) is characterized according to the invention in that the conductor carrier (5) comprises at least one number of contact elements (12) corresponding to the number of contact points (8), wherein the contact elements (12) are arranged in pairs to contact the contact points (8) of the two surface electrodes (7.21, 7.22) of each functional zone (7, 7', 7", 7‴), so that the two surface electrodes (7.21, 7.22) of each functional zone (7, 7', 7", 7‴) are contacted in the region of an edge (9) of the composite disk element (1).Furthermore, the present invention relates to a window (100) comprising a window frame (101) and at least one composite pane element (1) according to the invention incorporated therein, and to a method for producing a composite pane element according to the invention.