Encapsulated Flat Conductor Connection for Inspectable Solder Joints
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Solution Overview
Problem
The existing methods for connecting flat conductors in limited spaces, such as laminated glass panes, face challenges in quality control and versatility due to the inability to visually inspect soldering quality and reliance on specific soldering tools.
Innovation Solution
A flat conductor connection element with a capsule layer that exposes the connection and contact surfaces, allowing for easy soldering and quality inspection, and can be sealed to prevent moisture ingress, using a variety of soldering tools and materials like copper, aluminum, or silver foils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a hot stamping die is used for soldering through the electrically insulating cover, then soldering can be performed in confined spaces, but the soldering quality cannot be visually inspected
Solution Approach 1:
The electrically insulating cover is segmented by creating an opening in the region of the first connection area, separating the inspection function from the insulation function. This allows visual access to the soldering process while maintaining insulation coverage in other areas.
Solution Approach 2:
The opening in the electrically insulating cover acts as an intermediary that enables optical access for quality inspection while the cover itself maintains its insulating function. The opening serves as a mediator between the need for insulation and the need for visual inspection.
2Reliability
If the connection element is fully enclosed by an electrically insulating cover, then electrical insulation is maximized, but various soldering tools cannot be applied
Solution Approach 1:
The electrically insulating cover is divided into enclosed and open regions. The opening in the first connection area region allows various soldering tools to access the connection surface while the rest of the cover maintains full electrical insulation.
Solution Approach 2:
The electrically insulating cover has different properties in different regions: the region of the first connection area has an opening for tool access, while other regions remain fully enclosed for maximum insulation. This local differentiation resolves the contradiction between insulation and tool accessibility.
3Reliability
If the connection surface is exposed without an opening in the encapsulating layer, then electrical insulation is maintained, but quality control and soldering accessibility are reduced
Solution Approach 1:
The encapsulating layer is segmented with an opening in the region of the first connection area, allowing quality control inspection and soldering accessibility while maintaining insulation in the rest of the structure.
Solution Approach 2:
The opening extracts or removes the insulation material specifically in the region of the first connection area, creating a localized access point for quality control and soldering while preserving the insulation function elsewhere.
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
Enhances quality control and versatility in soldering, enabling the use of different soldering tools and ensuring reliable electrical connections while maintaining cost-effectiveness and ease of production.
Implementation Method 1
a contact surface 14 opposite the connection surface 13 for (touch) contact with a soldering tool for soldering the connection surface 13
Data Source
Figure 1~2
Figure 3~4A
Figure 4B~5
AI summary
The present invention relates to a flat-conductor connection element (1) for an electrically conductive structure (3), in particular an electrically conductive layer, applied to a pane (2), the flat-conductor connection element comprising: at least one conductor (4, 4'), containing a flat conductor (5), having a first connection region (9) at a first end (11) and a second connection region (10) at a second end (12), the first connection region (9) having a connection surface (13) for electrically connecting to the electrically conductive structure (3) and having a contact surface (14) opposite the connection surface for contact with a soldering tool; an encapsulation layer (15) made of an electrically insulating material, which encapsulation layer surrounds the conductor (4) at least in a conductor portion containing the first connection region (9), the encapsulation layer (15) having a through-hole (19), through which the connection surface (13) and the contact surface (14) of the first connection region (9) are accessible, the first connection region (9) of the conductor (4) being within the through-hole (19) in a view perpendicularly through the plane of the encapsulation layer (15). The present invention further relates to a connection assembly having a flat-conductor connection element of this type, the through-hole of which flat-conductor connection element is covered.