Pane Connection Element Assembly for Indirect Solder Heat Transfer
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Solution Overview
Problem
Existing vehicle window electrical connection systems face mechanical stress and contamination issues due to direct soldering methods, and increased production cycle times with flexible connection elements.
Innovation Solution
A pane with a rigid electrical connection element and connection cable, where the connection element has a first flat region for heat transfer to a soldering compound, allowing for indirect heating and reducing mechanical stress and contamination, with a method involving induction, resistance, or hot-air soldering to create a solder contact between the connection cable and conductive structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid connection element is used for electrical connection, then the electrical connection is stable and reliable, but shearing or leverage forces strain the solder connection when the connection cable is plugged in
Solution Approach 1:
The patent introduces a flexible connection element as an intermediary component between the rigid connection element and the connection cable. This flexible element absorbs mechanical stresses such as shearing and leverage forces during plugging operations, protecting the solder connection while maintaining electrical connectivity. The flexible element acts as a buffer that decouples the rigid structural support from the cable connection points.
2Strength
If flexible connection elements are used to minimize mechanical stresses, then the solder connection is protected, but the production cycle time increases
Solution Approach 1:
The flexible connection element is pre-assembled with the rigid connection element before the pane production process. This preliminary assembly allows the soldering operation to be performed on a stable, fixed structure rather than on a flexible element that would require additional handling and positioning time during production, thereby maintaining productivity while still providing stress protection.
3Productivity
If direct contact soldering method is used, then the soldering process is simple and fast, but the thermode causes contamination and wear due to direct contact with the solder joint
Solution Approach 1:
The patent introduces a heat-resistant foil as an intermediary layer between the thermode and the solder joint. This foil serves as a protective barrier that prevents direct contact between the thermode and the sensitive solder connection, thereby eliminating contamination and wear issues. The foil conducts heat effectively to maintain soldering speed while protecting the joint integrity.
4Temperature
If the thermode has a small cross-section for high electrical resistance heating, then high heating is achieved in the working area, but the region cools down quickly due to low thermal mass
Solution Approach 1:
The patent employs a composite structure consisting of the heat-resistant foil with specific thermal properties. The foil is designed with a composition that balances thermal conductivity for efficient heat transfer during soldering with sufficient thermal mass to retain heat briefly, preventing rapid cooling. This composite material approach allows the small cross-section thermode to maintain both high heating efficiency and improved heat retention.
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 reduces mechanical stress and contamination, standardizes production, and facilitates easy manufacturing by enabling efficient heat transfer for soldering without direct contact, resulting in a reliable and efficient electrical connection.
Implementation Method 1
the first flat region of the connection element is provided for transferring heat to the soldering compound
Implementation Method 2
a method involving induction, resistance, or hot-air soldering
Implementation Method 3
a method involving induction, resistance, or hot-air soldering
Data Source
AI summary
A pane has an electrical connection element and connection cable including a substrate, an electrically conductive structure on a region of the substrate, wherein the connection cable has, on its lower face facing the substrate, a contact region, in which a conductor track of the connection cable is connected to the region of the electrically conductive structure, the connection element is rigid and has a first flat region for contacting the connection cable, the connection element with the conductor track of the connection cable on an upper face of the connection cable facing away from the substrate is electrically conductively connected to the connection cable via a weld region, the contact region of the connection cable and the first flat region of the connection element are arranged one above the other such that the flat region of the connection element is provided for transferring heat to the soldering compound.