Glazing Solder Junction Reinforcement With Metallic Strip Sandwiching
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Solution Overview
Problem
Automotive glass industry faces weak durability of solder joints between electrical components due to improper manual soldering, especially in wire-like structures, leading to potential breakage.
Innovation Solution
A glazing design with a metallic strip sandwiching the solder junction between a connector and an electrical element, using lead-free solder material, ensuring a strong and reliable electrical connection by sandwiching the electrical element between the connector and the metallic strip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual soldering is used to connect electrical elements to connectors, then the manufacturing process is simple and flexible, but the durability and strength of solder joints deteriorate due to improper soldering technique
Solution Approach 1:
The patent applies preliminary action by pre-positioning the electrical element between the connector and the metallic strip before final soldering. This ensures proper alignment and positioning of the electrical element end, allowing the solder to flow uniformly and create a stronger, more reliable joint. The metallic strip acts as a pre-positioned support structure that guides the soldering process.
Solution Approach 2:
The metallic strip serves as an intermediary element between the connector and the electrical element. It provides mechanical support and structural reinforcement to the solder joint, distributing stresses and preventing direct stress concentration on the fragile solder connection. The metallic strip mediates the mechanical loads while allowing electrical continuity through the solder joint.
2Adaptability or versatility
If wire-like electrical elements are soldered manually, then the manufacturing process is flexible, but the solder joints have high tendency to break due to weak strength
Solution Approach 1:
The patent creates a composite structure consisting of the connector, solder material, electrical element, and metallic strip. This composite assembly combines the electrical conductivity of the solder and electrical element with the mechanical strength of the metallic strip and connector. The composite structure provides both electrical continuity and mechanical reinforcement, preventing breakage of wire-like elements.
Solution Approach 2:
The patent transitions from a simple linear connection to a multi-dimensional sandwich structure. The electrical element is positioned in between two solid structures (connector and metallic strip), creating a distributed stress configuration rather than a single-point connection. This dimensional change from 1D linear joint to 2D sandwich structure significantly enhances joint strength.
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 enhances the strength of solder joints, preventing breakage and ensuring uninterrupted current transport, while maintaining the efficiency of electrical elements.
Implementation Method 1
the soldering is done by heating up the solder area... the solder material is heated up by the solder gun
Implementation Method 2
the solder material is heated up by the solder gun... through a lead-free solder material
Data Source
AI summary
A glazing includes a window pane and an electrical element engaged to the window pane. The glazing also includes a connector connected to the electrical element defining a solder junction therebetween. The connector is adapted to electrically connect the electrical element to an electric source. The glazing also includes at least one metallic strip engaged to the solder junction and arranged covering the solder junction. At least one metallic strip is arranged such that at least one end of the electrical element is sandwiched between the connector and the at least one metallic strip.