Polymer Disc Conductive Structure With Integral Fastening
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Solution Overview
Problem
Existing methods for integrating electrically conductive structures into plastic vehicle windows for heating or antenna functions are complex, prone to errors, and difficult to connect reliably to the on-board electrical system, lacking effective screen printing pastes and stable electrical contacting solutions.
Innovation Solution
A polymer pane with an electrically conductive structure featuring a polymeric substrate, elastic conductive contacting bars, and integral fastening elements that clamp the contacting bars to the substrate, allowing for simple and stable electrical connection without additional processing steps like soldering or drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wires or busbars are applied to a thin plastic film and connected to the disc body by back injection molding, then the electrically conductive structure can be implemented, but the wires and busbars are not easy to connect to the on-board electrical system since they are not accessible from the outside
Solution Approach 1:
Instead of routing wire ends beyond the pane edge for external connection, the invention inverts the approach by creating integral fastening elements directly on the disc body surface that clamp onto the conductor tracks. This makes the electrical connection points accessible from the outside while keeping the connection structure simple and integrated.
Solution Approach 2:
The integral fastening elements are self-contained features molded directly into the disc body, eliminating the need for separate mounting hardware or complex assembly steps. The fastening elements automatically provide both mechanical support and electrical connection functionality when the contacting bar is clamped onto them.
2Ease of manufacture
If a metal layer is introduced into the pane during film back-injection to provide electrical contact, then electrical contacting can be achieved, but the production of the pane becomes complex and error-prone and is limited to panes produced according to that specific method
Solution Approach 1:
The invention separates the electrical connection function into distinct components: the conductor track on the disc body and the contacting bar with integral fastening elements. This segmentation allows the connection mechanism to be designed and manufactured independently of the disc body production method, providing flexibility to use different manufacturing processes without limiting the overall system.
Solution Approach 2:
The contacting bar serves multiple functions: it provides electrical connection to the conductor track, mechanical support through integral fastening elements, and accessibility for connection to the on-board electrical system. This multi-functionality reduces the need for additional components and simplifies the overall production process.
3Reliability
If wires are thermally embedded in the surface of the plastic body with connection elements welded to them, then electrical connection can be achieved, but the electrical contact is prone to errors and the connection element fastening to the disc body is not reliably taught
Solution Approach 1:
The invention merges the fastening function and electrical connection function into a single integrated structure: the contacting bar with integral fastening elements. This eliminates the need for separate welding or fastening operations that could introduce errors, while providing reliable mechanical support and electrical connection simultaneously.
Solution Approach 2:
The invention replaces the thermal embedding and welding process with a mechanical clamping system. The contacting bar is clamped onto the disc body surface using integral fastening elements, which provides a reliable electrical connection without the errors associated with thermal processes while maintaining a simple connection structure.
4Reliability
If screen printing paste is used to create electrically conductive structures on plastic surfaces, then the structure can be applied, but the electrical conductivity is not sufficient for effective heating
Solution Approach 1:
The invention uses a contacting bar made of electrically conductive material (such as metal) that provides sufficient electrical conductivity for effective heating. The integral fastening elements are molded from polymeric material, creating a composite structure that combines high electrical conductivity with mechanical fastening capability, resolving the contradiction between conductivity and manufacturing simplicity.
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 provides a stable, reliable, and easy-to-produce electrically conductive structure for polymer panes, enabling efficient electrical contacting and maintaining a permanent connection, which is more stable than traditional methods and adaptable for various applications, including heating functions.
Implementation Method 1
at least one electrically conductive, elastic contacting bar, which is electrically connected to a portion of the conductor track arranged between the polymeric substrate and the contacting bar
Data Source
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AI summary
The invention relates to a polymeric panel (I) having an electrically conductive structure, at least comprising a polymeric substrate (1) having at least one conductive track (2) on a surface (12) of the polymeric substrate (1), at least one electrically conductive resilient contacting rail (3) electrically connected to a portion of the conductive track (2) that is arranged between the polymeric substrate (1) and the contacting rail (3), and at least one fastening element (4) by means of which the contacting rail (3) is clamped onto the surface (12) of the polymeric substrate (1), wherein the fastening element (4) is formed integrally with the polymeric substrate (1).