Laminated Glass Electrode Connection Using Folded Flexible Busbars

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Solution Overview

Problem

The existing connection methods for electro-optical functional elements in composite panes risk damaging the surface electrodes during soldering and are inefficient in terms of material usage and production costs.

Innovation Solution

A connection arrangement featuring a composite pane with a single busbar per surface electrode, designed as a flexible, foldable strip of electrically conductive material that is applied directly to the surface electrodes without the need for additional soldering, reducing material and labor costs while avoiding electrode damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional soldering methods are used to connect busbars to surface electrodes, then electrical connection is achieved, but the surface electrodes are at risk of damage

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidelectrode damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent extracts the harmful soldering process from the connection method and replaces it with a mechanical pressing connection. The busbar is connected to the surface electrode through direct contact and pressing force, eliminating the need for soldering and thus removing the risk of thermal damage to the electrodes while maintaining electrical connectivity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces an intermediate adhesive layer that serves as a mediator between the busbar and the surface electrode. This adhesive layer enables electrical connection through conductive properties while protecting the electrode from direct mechanical and thermal stress during the connection process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If multiple separate components are used for electrical connection, then connection flexibility is improved, but material usage and production costs increase

Engineering Contradiction:

Improveconnection flexibilityVSAvoidmaterial usage efficiency

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The patent merges the busbar and its connection structure into a single integrated component. The busbar is designed as one piece that directly contacts the surface electrode, eliminating the need for separate soldering materials, additional connectors, and multiple assembly steps, thus reducing material usage while maintaining connection flexibility.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If traditional multi-step connection processes are used, then connection reliability is achieved, but manufacturing complexity and production time increase

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-forming the busbar with the appropriate shape and contact surfaces during its manufacturing process. This allows the busbar to be directly pressed onto the surface electrode without requiring additional shaping, cutting, or preparation steps during assembly, thereby simplifying the manufacturing process while ensuring reliable connection.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the complex thermal-mechanical soldering system with a simpler mechanical pressing system. Instead of requiring heating equipment, solder materials, and precise temperature control, the connection is achieved through mechanical pressure applied during lamination, significantly reducing manufacturing process complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enables a cost-effective, material-saving, and damage-free electrical connection of surface electrodes, allowing for efficient integration and operation of electro-optical functional elements in composite panes.

Implementation Method 1

a bus conductor (16) with a first connection area (19) which is applied to the associated surface electrode (7, 8) and has contact contact with the surface electrode (7, 8)

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP4100250B1Connection assembly with laminated glass and functional element

Publication Date: 2023.11.22 SAINT GOBAIN VITRAGE SA

Figure 1~2
Figure 3A~3C
Figure 4

AI summary

The present invention relates to a connection assembly (1), comprising: a composite pane (2), which is composed of a first pane (3) and a second pane (4), which are connected to an intermediate layer (5), an electro-optical functional element (6) having an active layer (11) arranged between two flat electrodes (7, 8), which electro-optical functional element is arranged between the first pane (3) and the second pane (4), a single flexible collecting line (16) in the form of a strip being applied to each of the two flat electrodes (7, 8), each collecting line (16) being folded over and led out of the composite pane (2).