Glass Surface Conductor Connection Using Elastic Press Contact
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Solution Overview
Problem
Conventional electrical connection methods for conductors on glass surfaces, such as those used in automotive rear window glass, face issues like reduced glass strength due to thermal shock from soldering, compliance with lead-free solder regulations, and complex designs, while existing alternatives are costly and difficult to assemble.
Innovation Solution
An electrical connection structure that uses a housing with a cover member and an elastic connection member to establish contact with the conductor on the glass surface without soldering, featuring a releasable upper cover part and an adhesive for secure attachment, allowing for easy part exchange and reduced part count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect terminal to baked silver paste, then electrical connection is achieved, but glass strength is reduced due to thermal shock
Solution Approach 1:
The patent replaces the thermal soldering process with a mechanical pressing system. A pressing member applies elastic force to press the terminal against the baked silver paste, establishing electrical connection without thermal input that would cause glass strength reduction.
Solution Approach 2:
The patent introduces a pressing member as an intermediary component between the terminal and the baked silver paste. This pressing member transmits mechanical force to ensure reliable electrical contact while isolating the glass from direct thermal exposure during connection establishment.
2Reliability
If lead-containing solder is used for connection, then electrical connection is achieved, but compliance with lead-free regulations is violated
Solution Approach 1:
The patent eliminates the need for soldering entirely by using a mechanical pressing system. This substitution removes dependency on lead-containing solder, enabling compliance with lead-free regulations while maintaining reliable electrical connection through elastic pressing force.
3Reliability
If terminal is attached in bare state to bus bar portion, then electrical connection is achieved, but external appearance is affected
Solution Approach 1:
The patent merges the terminal attachment function with a cover structure. The cover member encloses the terminal and pressing mechanism, hiding them from external view while maintaining the electrical connection function, thus resolving the conflict between connection reliability and aesthetic appearance.
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 solution provides a stable, low-cost, and space-saving electrical connection that prevents glass scratching and eliminates the need for lead solder, simplifying assembly and improving the external appearance while maintaining effective electrical conductivity.
Implementation Method 1
a connection member (7) inserted into the insertion slot (5), made of an electrically conductive material having elasticity, wherein the connection member presses the conductor (2) by being elastically deformed in the cavity (9)
Data Source
AI summary
An electrical connection structure for a conductor formed on a glass surface, including a conductor formed on a glass surface, a housing having a cover member provided to cover at least a part of the conductor, forming a cavity between the cover member and the glass surface and having an insertion slot in communication with the cavity, and a connection member inserted into the insertion slot made of an electrically conductive material having elasticity. The connection member presses the conductor by being elastically deformed in the cavity whereby the connection member and the conductor are electrically connected. The cover member includes a releasable plate-shaped ceiling forming in its open position an angle (α) between the glass surface and the cover member from 15 to 135°.