Segmented Switchable Composite Pane With Robust Busbar Contacting
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Solution Overview
Problem
Conventional electrically controllable sun visors in vehicles face challenges with inhomogeneous switching behavior and reduced service life due to difficulties in ensuring homogeneous electrical contacting, especially in small segments, leading to increased power consumption and component failure.
Innovation Solution
A composite pane with a functional element that includes surface electrodes divided by isolating lines, allowing for individual segment control, with busbars extending beyond the segment width to maximize length and ensure robustness, and a multilayer film structure for protection and easy integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the size of the functional element segments is reduced to enable individual control, then the adaptability and control precision are improved, but the area available for electrical contacting decreases, leading to inhomogeneous switching behavior and increased risk of component failure
Solution Approach 1:
The patent divides the functional element into multiple independently controllable segments by introducing isolating lines that extend through the active layer and surface electrodes. This segmentation enables individual control of each segment while maintaining reliable electrical contacting within each segment, resolving the contradiction between segment control capability and electrical contact reliability.
Solution Approach 2:
The patent extends busbars beyond the width of their associated segments in the lateral direction, utilizing additional spatial dimensions. This extension provides larger contact areas and more robust electrical connections without increasing the segment size, thereby maintaining reliability while enabling fine segment control.
2Reliability
If busbars are made larger to ensure robust electrical contacting, then the electrical contact reliability is improved, but the device complexity and space requirements increase
Solution Approach 1:
The patent combines multiple functions into the busbar structure: electrical conductive contact, mechanical support, and spatial organization. By extending busbars laterally beyond segment boundaries, they serve both as electrical contacts and as structural elements that define segment boundaries and provide mounting surfaces, reducing overall device complexity.
Solution Approach 2:
The busbars are designed to perform multiple functions simultaneously: providing electrical contact, extending laterally to define segment boundaries, and serving as mounting surfaces for surface electrodes. This multi-functionality reduces the need for separate components, thereby reducing device complexity while maintaining reliable electrical contacting.
3Use of energy by moving object
If the active layer is switched in small segments with reduced contact area, then the energy consumption is reduced, but the inhomogeneity of surface electrodes increases, leading to locally elevated power consumption and heating
Solution Approach 1:
The patent incorporates isolating lines during the manufacturing process that pre-defin e segment boundaries and protect surface electrodes from damage before electrical contacting is established. This preliminary action prevents inhomogeneities from developing, ensuring uniform power distribution across all segments during operation.
Solution Approach 2:
The isolating lines act as intermediaries that separate adjacent segments electrically while allowing the busbar structure to provide extended contact areas. This intermediary structure prevents local inhomogeneities in surface electrodes from causing elevated power consumption and heating, enabling efficient operation of small segments.
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 enables selective and reliable control of the active layer in segments, enhancing the service life and reducing the risk of failure by ensuring homogeneous voltage distribution and robust electrical connections.
Implementation Method 1
When a voltage is applied to the surface electrodes, the liquid crystals align themselves in a common direction and the transmittance of light through the active layer is increased
Implementation Method 2
When no voltage is applied, the liquid crystals are randomly oriented, resulting in strong scattering of the light passing through the active layer
Data Source
AI summary
A composite pane having an electrically controllable functional element that can be switched in segments, includes first and second panes joined to one another via an intermediate layer, and a functional element with a plurality of side edges embedded in the intermediate layer. The functional element includes, arranged flat one over another, a first surface electrode and a second surface electrode, between which an active layer is arranged flat. The first surface electrode is divided into multiple segments by a separating line. A group of first busbars electrically conductively contact the first surface electrode, and each segment of the first surface electrode is electrically conductively contacted by one busbar from the group of the first busbars. A second busbar electrically conductively contacts the second surface electrode.