Pane Cable Connection Element for Low-Stress Soldered Contacts

Solution Overview

Problem

Existing disc manufacturing processes with electrical connection elements face challenges such as mechanical stress on soldering connections due to plug-in cables, increased cycle times, and environmental concerns related to traditional soldering methods.

Innovation Solution

A disc design featuring a stiff connection element with a first flat area for heat transfer, allowing for soldering without direct contact, using induction, resistance, or hot air soldering, and employing a lead-free soldering mass to reduce mechanical stress and environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a rigid connection element is used, then the electrical connection is stable, but shear or leverage forces occur when connecting the cable, stressing the soldered connection

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidsoldered connection strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The connection element is divided into two distinct parts: a rigid portion for stable electrical connection and a flexible portion for stress absorption during cable connection. This segmentation allows each part to fulfill its specific function - the rigid part ensures electrical stability while the flexible part protects the soldered connection from mechanical stresses

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flexible portion acts as an intermediary element between the rigid connection element and the connecting cable. It mediates the mechanical stresses by absorbing shear and leverage forces, preventing them from being transmitted to the soldered joint while still maintaining electrical conductivity

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If a flexible connection element is used, then mechanical stresses are minimized, but the connection element cannot provide stable rigid electrical connection

Engineering Contradiction:

Improvesoldered connection strengthVSAvoidelectrical connection stability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The connection element is divided into two distinct parts: a rigid portion for stable electrical connection and a flexible portion for stress absorption during cable connection. This segmentation allows each part to fulfill its specific function - the rigid part ensures electrical stability while the flexible part protects the soldered connection from mechanical stresses

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the connection element have different mechanical properties - the first portion is rigid to ensure stable electrical connection, while the second portion is flexible to absorb mechanical stresses. This local differentiation of material properties allows the single component to satisfy both contradictory requirements

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If direct contact soldering is used, then the soldering process is simple, but contamination and wear occur on the thermode

Engineering Contradiction:

Improvesoldering process simplicityVSAvoidthermode condition

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The flat area of the connection element serves as an intermediary surface between the soldering device and the solder joint. It allows heat transfer for soldering while preventing direct contact between the thermode and the solder, thereby avoiding contamination and wear on the soldering tool

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention replaces direct mechanical contact soldering with indirect contact soldering through the flat area. Instead of the thermode directly touching the solder joint, heat is transferred through the flat area of the connection element, substituting a mechanical contact system with a thermal conduction system that avoids contamination

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Strength

If flexible connecting elements are used, then mechanical stresses are reduced, but the production cycle time increases

Engineering Contradiction:

Improvesoldered connection strengthVSAvoidproduction cycle time

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The connection element is divided into two distinct parts: a rigid portion for stable electrical connection and a flexible portion for stress absorption during cable connection. This segmentation allows each part to fulfill its specific function - the rigid part ensures electrical stability while the flexible part protects the soldered connection from mechanical stresses

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the connection element have different mechanical properties - the first portion is rigid to ensure stable electrical connection, while the second portion is flexible to absorb mechanical stresses. This local differentiation of material properties allows the single component to satisfy both contradictory requirements

Inventive Principle:

Principle #3Local quality

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 design minimizes mechanical loads during cable connection, standardizes manufacturing processes, and ensures a reliable, environmentally friendly electrical connection between the connection cable and conductive structure, enhancing production efficiency and environmental compatibility.

Implementation Method 1

The flat area of the connection element is designed to transfer heat to a solder mass located in the contact area

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

This device can be used for induction, resistance, or hot air soldering

Methodology Applied

Scientific EffectInduction heating: Induction Heating

Implementation Method 3

This device can be used for induction, resistance, or hot air soldering

Methodology Applied

Scientific EffectResistance heating: Joule Heating

Implementation Method 4

The soldered contact is achieved by melting the solder, which, upon subsequent cooling or solidification, creates an electrically conductive connection

Methodology Applied

Scientific EffectMelting and solidification: Melting

Data Source

PatentEP3815462B1Pane with electric connection element and connecting cable

Publication Date: 2023.03.08 SAINT GOBAIN VITRAGE SA

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AI summary

The present invention relates to a pane having at least one electrical connection element (2) and connection cable (3), at least comprising: ° a substrate (1), ° an electrically conductive structure (5) on a region of the substrate (1), wherein: ° the connection cable (3) has on the lower face thereof facing the substrate (4) a contact region (7) in which a conductor (3.1) of the connection cable (3) is connected to the region of the electrically conductive structure (5); ° the connection element (2) is rigid and has a first flat region (2.1) for making contact with the connection cable (3); ° the connection element (2) is electrically connected to the connection cable (3) by the conductor (3.1) of the connection cable (3) via a weld region on an upper face of the connection cable (3) facing away from the substrate (4); ° the contact region (7) of the connection cable (3) and the first flat region (2.1) of the connection element (2) are arranged one above the other such that the flat region (2.1) of the connection element is provided to transfer heat to the solder compound.