Plug-In Flat Conductor Connection for Solder-Free Cable Assembly

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Solution Overview

Problem

The labor-intensive process of electrical contacting in composite panes with functional elements, particularly in laminated glass panels, where each segment must be individually contacted using flat conductors and manual soldering, is time-consuming and inefficient.

Innovation Solution

A substrate with a functional element featuring an electrical line connection with a cross-sectional transition region that includes a plug connection between a flat conductor and a cable, allowing for automatic assembly and eliminating the need for soldering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual soldering is used to connect flat conductors to cables, then reliable electrical connection is achieved, but the production process becomes extremely time-consuming and labor-intensive

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidproduction speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the thermal-mechanical soldering process with a purely mechanical plug connection system. The flat conductor with integrated plug can be directly inserted into the cable connector without heating, soldering, or complex manual operations, thereby eliminating the time-consuming soldering step while maintaining reliable electrical contact through the mechanical plug structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The plug connection is pre-integrated into the flat conductor structure during manufacturing, so that during assembly, the electrical connection is already prepared and only requires simple insertion. This preliminary preparation of the connection interface eliminates the need for on-site soldering operations.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If manual step-by-step contacting is performed for each segment, then precise electrical connections are established, but the number of work steps increases significantly

Engineering Contradiction:

Improveelectrical contacting precisionVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges multiple separate contacting operations into a single integrated plug connection. Instead of performing separate soldering operations for each conductor-cable connection, the flat conductor is designed with an integrated plug that establishes all necessary electrical connections through one insertion action, thereby reducing process complexity while maintaining precision.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The plug connection design serves multiple functions simultaneously: it provides mechanical support, ensures electrical contact, and enables simple assembly. This multi-functional design eliminates the need for separate dedicated contacting steps for each function, reducing the overall number of work steps.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If soldering is used to join cable conductors to flat conductor tracks, then electrical connection is achieved, but mechanical stresses are introduced during the energy introduction process

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidmechanical stress

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent eliminates the soldering process that introduces thermal and mechanical stress by replacing it with a cold mechanical plug connection. The electrical connection is established through direct mechanical contact of the plug with the connector, avoiding the high temperatures and thermal expansion/contraction cycles that cause mechanical stress and potential damage to the delicate conductor tracks and functional elements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP4222817B1Electrical line connection for electrically contacting a flat electrode

Publication Date: 2025.06.18 SAINT GOBAIN SEKURIT FRANCE

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AI summary

The invention relates to a substrate having a functional element comprising an electrical line connection (10) with a cross-sectional transition region (11) from a flat conductor (1), which comprises a carrier substrate and at least one conductor track (1.2), to a cable (2), which comprises at least one electrical conductor (2.1), wherein at least one electrical connection between the at least one conductor track (1.2) and the cable (2) is provided in the cross-sectional transition region (11), characterized in that the cross-sectional transition region (11) has a plug-in connection for establishing an electrical connection between the flat conductor (1) and the cable (2), wherein the plug-in connection comprises two connecting elements (1.4 A, 1.4 B, 2.2, 2.3 A, 2.3 B, 2.4), wherein in each case a conductor track (1.2) of the flat conductor (1) is provided for connection to a conductor (2.1) of a cable (2) via the plug-in connection and wherein the cable (2) has a second connecting element (2.2, 2.3 A, 2.3 B, 2.4) which has, in particular, a receptacle for connection to a first connecting element (1.4 A, 1.4 B) in the form of a socket (2.3 B) or a plug-in contact (2.3 A).