Insulated Glazing Connector Film for Hidden Busbar Contacting
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Solution Overview
Problem
Insulated glazings with electrochromic properties or electrically controllable liquid crystal layers face aesthetic issues due to visible busbars, which are unsightly and reduce the visible region of windows, and existing solutions like opaque coatings or components are not aesthetically pleasing or effective in concealing busbars from both inside and outside perspectives.
Innovation Solution
A connecting element comprising a flat conductor on an electrically insulating carrier film with solder deposits and adhesive layers, where the conductor is arranged completely on the film to prevent damage and is soldered to busbars, ensuring electrical connection while being concealed by opaque films, enhancing aesthetic appeal and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbars are used for electrical connection in insulated glazing, then electrical functionality is achieved, but aesthetic appearance deteriorates due to visible busbars reducing the visible region and being unsightly
Solution Approach 1:
The busbar is extracted from the visible glazing interior space and relocated to the exterior side, where it is concealed by the spacer and sealing elements. Only the necessary connection regions protrude into the glazing interior, minimizing visual impact while maintaining electrical functionality.
Solution Approach 2:
The busbar connection is moved from the two-dimensional plane of the glass surface to the three-dimensional exterior space, allowing the busbar to be positioned behind the spacer and sealed edge, effectively hiding it from view while preserving its electrical connection function.
2Shape
If opaque coating is applied to conceal busbars, then aesthetic appearance improves from outside view, but visible region is excessively restricted and aesthetic appeal from inside view deteriorates
Solution Approach 1:
Instead of applying opaque coating to the glass surface, the busbar itself is extracted and relocated to the exterior side of the glazing, where it is naturally concealed by the spacer and sealing structure, eliminating the need for aesthetic-compromising coatings.
Solution Approach 2:
The busbar is designed with an aesthetic appearance suitable for exterior visibility, eliminating the need for opaque coatings that would restrict the visible region. The connection regions are minimized and strategically positioned to maintain aesthetic appeal from both inside and outside views.
3Reliability
If busbars are positioned in glazing interior space, then electrical connection is achieved, but aesthetic appearance deteriorates as busbars are visible from both inside and outside
Solution Approach 1:
The busbar is extracted from the glazing interior space and repositioned to the exterior side, where it is concealed by the spacer and sealing elements. Only minimal connection regions are allowed to protrude into the interior space, effectively hiding the busbar from both inside and outside views while maintaining electrical connection.
Solution Approach 2:
Instead of placing the busbar inside the glazing and trying to conceal it, the approach is inverted by placing the busbar outside the glazing and using the existing exterior structures (spacer, sealing elements) to conceal it, achieving better aesthetic results.
4Strength
If flat conductor is arranged completely on carrier film, then mechanical protection and aesthetic concealment are improved, but electrical connection complexity increases requiring precise soldering
Solution Approach 1:
The flat conductor is pre-positioned and fixed to the carrier film at the appropriate location before the final assembly. The connection regions are prepared in advance with solder deposits, allowing for precise and efficient soldering to the busbar without requiring complex alignment procedures during assembly.
Solution Approach 2:
The carrier film serves as an intermediary substrate that holds the flat conductor in the correct position and provides a stable base for soldering. This intermediary structure simplifies the connection process by pre-establishing the geometric relationship between the conductor and the busbar connection points.
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 effectively conceals busbars from both inside and outside views, improving the aesthetic appearance of insulated glazings while maintaining electrical functionality and mechanical integrity, and reduces the risk of short circuits during the burning-in process.
Implementation Method 1
at least one first connection region with at least one first solder deposit and at least one second connection region with at least one second solder deposit
Implementation Method 2
at least one second adhesive layer, which is arranged below and/or next to the second connection region on a second side of the carrier film facing away from the first side
Data Source
AI summary
A connecting element, in particular for contacting an electrically conductive coating and/or an electrically controllable functional element in an insulated glazing, includes at least one flat conductor, which is arranged on a first side of an electrically insulating carrier film, and the flat conductor has at least one first connection region with at least one first solder deposit and at least one second connection region with at least one second solder deposit, and at least one second adhesive layer, which is arranged below and/or next to the second connection region on a second side of the carrier film facing away from the first side.