Mixed Braid Ribbon Conductor for Vehicle Window Electrical Connections
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Solution Overview
Problem
Existing electrical connection elements for vehicle windows face challenges in maintaining electrical conductivity and mechanical strength under thermal stress, particularly due to the mismatch in thermal expansion between copper solder connection parts and glass panes, leading to potential brittleness and reduced tensile strength when using lead-free solder materials with different melting points.
Innovation Solution
An electrical connection element featuring a mixed braid ribbon conductor with individual wires of copper and ferritic chromium steel, where the proportion of higher melting temperature wires (15-85%) maintains tensile strength and electrical conductivity, and a steel alloy solder connection part with a bridge design to accommodate thermal expansion differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper solder connection part is used, then electrical conductivity is improved, but thermal expansion mismatch with glass causes mechanical stress
Solution Approach 1:
The patent applies composite materials by creating a mixed braid consisting of copper wires (for electrical conductivity) and stainless steel wires (for mechanical strength and thermal expansion compatibility). This composite structure allows the connection element to simultaneously achieve good electrical conductivity while resisting thermal stress through the stainless steel component that better matches the thermal expansion characteristics of glass.
2Adaptability or versatility
If lead-free solder materials with different melting points are used, then environmental requirements are met, but tensile strength and mechanical properties are significantly impaired
Solution Approach 1:
The patent uses composite materials in the mixed braid where stainless steel wires provide the mechanical strength and tensile strength that would otherwise be compromised by using lead-free solder materials. The copper wires maintain electrical conductivity while the stainless steel reinforcement ensures mechanical integrity under thermal cycling conditions.
Solution Approach 2:
The patent applies local quality by having different wire materials perform different functions within the same braid structure. The copper wires are optimized for electrical conductivity and ease of soldering, while the stainless steel wires are specifically positioned to provide mechanical strength and resistance to thermal stress at critical locations within the connection element.
3Reliability
If welding process is used to connect ribbon strand to solder connection part, then electrical connection is achieved, but thermal stress causes annealing and brittleness
Solution Approach 1:
The patent applies composite materials by incorporating stainless steel wires into the mixed braid that are more resistant to thermal stress and annealing than pure copper. During the welding process, the stainless steel wires maintain their mechanical strength while the copper wires provide electrical conductivity, resulting in a connection that achieves reliable electrical contact without significant brittleness development.
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 provides an electrical connection element with enhanced tensile strength and thermal resistance, ensuring the mechanical properties are preserved under thermal stress, and the connection remains robust and conductive, with the stainless steel wires compensating for copper damage during welding.
Implementation Method 1
Since the solder connection part is made of copper, there is the disadvantage that the expansion when the temperature changes behaves differently than the expansion of the corresponding pane of glass. In order to reduce the resulting mechanical stress
Implementation Method 2
An electrical connection element for fastening, i. H. Soldered to a glass pane and assumed conductive sections present there... consisting of a solder connection part and a ribbon strand section fixed to the solder connection part by welding
Implementation Method 3
The solder connection part can have an offset, in particular an offset middle part, in order to form a deformable bridge which reduces the thermal stresses caused by the different thermal expansion of the glass and the soldered sheet metal part
Data Source
AI summary
The invention relates to an electrical connection element for fastening, in particular soldering, to a glass pane and conductive sections present there, in particular to a vehicle window, consisting of a solder connection part and a ribbon litz wire section fixed to the solder connection part by welding. According to the invention, the ribbon litz wire section consists of a mixed braid which, in addition to single wires made of copper or a copper alloy, contains single wires made of a material which has a melting temperature that corresponds substantially to the melting temperature of the solder connection part or has a higher melting temperature than the latter.