Floating Connectors for Smart Window Electrical Integration
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Solution Overview
Problem
Existing electrochromic window systems face challenges in efficiently delivering power to electrochromic glazings through framing and related structures, leading to complexities in integration and installation, particularly in retrofit applications and in ensuring reliable electrical connections during the handling and transportation of Insulated Glass Units (IGUs).
Innovation Solution
The development of connectors and electrical connection systems for optically switchable devices, including electrochromic devices, which involve a wire assembly with a floating connector and ferromagnetic elements for secure electrical communication, and the use of pre-wired spacers and flexible ribbon cables to provide power and communication to electrochromic devices within IGUs, allowing for flexible installation and protection of wires during movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wiring methods are used to deliver power to electrochromic glazings through framing structures, then electrical connections can be established, but the integration becomes complex and installation becomes difficult
Solution Approach 1:
The electrical connection system is divided into separate modular components: a connector attached to the IGU edge and a separate wiring harness that connects to the frame. This segmentation allows each component to be optimized independently and simplifies installation by enabling separate attachment and connection steps.
Solution Approach 2:
The connector is pre-attached to the IGU edge during manufacturing, establishing the electrical connection point before the IGU is installed in the frame. This preliminary action eliminates the need for complex wiring integration during installation and ensures reliable electrical connections are already in place.
2Ease of operation
If wires are exposed during handling and transportation of IGUs, then electrical connections can be accessed, but the wires are vulnerable to damage
Solution Approach 1:
The wires are nested within a protective conduit or housing that runs along the IGU edge. The connector is integrated into this protective structure, allowing electrical access while the wires remain enclosed and protected from mechanical damage during handling and transportation.
Solution Approach 2:
A flexible protective sheath or coating is applied to the wires and connector assembly, providing mechanical protection while maintaining flexibility for connection. This flexible barrier protects the electrical components from damage during installation and use.
3Strength
If rigid connector structures are used for mounting to frames, then mechanical strength is provided, but flexibility in positioning electrical connections is reduced
Solution Approach 1:
The connector incorporates flexible elements such as spring-loaded contacts, flexible printed circuit boards, or adjustable mounting mechanisms that allow the electrical connection points to be positioned at various locations along the IGU edge while maintaining mechanical strength through the overall rigid connector structure.
Solution Approach 2:
The connector structure has different mechanical properties in different regions: rigid mounting portions for secure attachment to the frame, and flexible or adjustable portions for electrical connection that can accommodate varying positions. This local differentiation of mechanical properties provides both strength and positioning flexibility.
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
These solutions enable efficient and flexible powering of electrochromic devices, reduce the risk of damage during handling and installation, and provide secure electrical connections, enhancing the reliability and ease of integration of electrochromic windows in various applications.
Implementation Method 1
The second connector includes a surface having contacts and the surface is shaped for mechanical engagement to the first connector. The second connector further includes a second ferromagnetic element, which itself may be magnetized. At least one of the first and second ferromagnetic elements is magnetized such that the first and second connectors may magnetically engage one another to provide electrical communication between their respective contacts.
Data Source
AI summary
This disclosure provides connectors for smart windows. A smart window may incorporate an optically switchable pane. In one aspect, a window unit includes an insulated glass unit including an optically switchable pane. A wire assembly may be attached to the edge of the insulated glass unit and may include wires in electrical communication with electrodes of the optically switchable pane. A floating connector may be attached to a distal end of the wire assembly. The floating connector may include a flange and a nose, with two holes in the flange for affixing the floating connector to a first frame. The nose may include a terminal face that present two exposed contacts of opposite polarity. Pre-wired spacers improve fabrication efficiency and seal integrity of insulated glass units. Electrical connection systems include those embedded in the secondary seal of the insulated glass unit.