Transparent Electrical Connector Structure to Prevent Hot Melting
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Solution Overview
Problem
Existing electrical connecting portions for vehicle lamps with heating functions face reliability issues due to hot melting and unstable conduction at the interconnection between the electrically conductive coating and the circuit board, leading to poor heat transfer and illumination obstruction in snowy conditions.
Innovation Solution
An electrical connecting portion comprising a light-transmittable substrate with two copper layers and electrically conductive coating layers, where the copper layers have through-holes filled by the conductive coating layers, creating an insulating spacing and reducing heat generation by diverting current flow, thereby preventing hot melting and enhancing stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical conduction is performed at the interconnection between the electrically conductive coating and the circuit board, then heating function is achieved, but hot melting occurs leading to unstable connection
Solution Approach 1:
The electrical connecting portion is divided into multiple copper layers (first copper layer, second copper layer) with insulating layers between them. This segmentation distributes the electrical conduction path and reduces heat concentration at any single interconnection point, preventing hot melting while maintaining heating functionality.
Solution Approach 2:
Insulating layers are introduced as intermediary elements between the electrically conductive coating and the copper layers, and between different copper layers. These intermediaries manage heat distribution and prevent direct thermal contact that would cause hot melting, while still allowing electrical conduction through the structured pathway.
2Power
If larger heat energy is generated at the interconnection, then heating effect is enhanced, but the conductive coating hot melts causing bad connection
Solution Approach 1:
Different layers are assigned different functional qualities: copper layers provide high electrical conductivity and heat dissipation, insulating layers provide thermal isolation and structural support, and the electrically conductive coating provides the heating function. This local differentiation allows heat energy to be generated and managed at appropriate locations without causing hot melting.
Solution Approach 2:
The electrical connecting portion uses a composite structure combining copper layers, insulating layers, and electrically conductive coating. This composite material approach leverages the advantages of each material (copper's conductivity, insulator's thermal management, coating's heating capability) to achieve stable high-power operation without hot melting.
3Reliability
If copper layers are added to the electrical connecting portion, then heat-resistant reliability is improved, but device complexity increases
Solution Approach 1:
The electrical connecting portion uses a nested structure where the first copper layer and second copper layer are positioned at different heights with insulating layers between them, creating a compact multi-layer configuration. This nesting approach improves heat-resistant reliability by distributing thermal load while maintaining a space-efficient design that minimizes overall structural complexity.
Solution Approach 2:
The solution transitions from a planar single-layer design to a three-dimensional multi-layer structure. By adding the vertical dimension with stacked copper layers and insulating layers, the patent achieves improved heat management and reliability without significantly increasing the horizontal footprint, thus balancing complexity improvement with functional enhancement.
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 provides a stable and reliable electrical connection that reduces heat generation at the conductive coating layers, preventing hot melting and ensuring consistent illumination by maintaining electrical conductivity and mechanical integrity, even in snowy conditions.
Implementation Method 1
The heating element generates heat energy to heat the lens of the vehicle lamp through conduction by the electrical connecting end
Implementation Method 2
The heating element generates heat energy to heat the lens of the vehicle lamp through conduction by the electrical connecting end
Implementation Method 3
the two electrically conductive coating layers are electrically connected to a heating element of the heating unit of the device
Implementation Method 4
Since a larger heat energy is generated at an interconnection between the electrical connecting end of the electrically conductive coating and the circuit board after electrical conduction
Data Source
AI summary
An electrical connecting portion for a device with a heating function is a portion of a heating unit of the device. The electrical connecting portion includes a substrate, two copper layers, and two electrically conductive coating layers. The substrate is made of a light-transmittable material and includes a front face and a rear face. Each of the two copper layers includes at least one first through-hole extending in a front-rear direction. Each of the two electrically conductive coating layers substantially covers a respective one of the two copper layers and is coupled to the front face of the substrate. Each of the two electrically conductive coating layers substantially fills the at least one first through-hole of the respective one of the two copper layers. The two electrically conductive coating layers have an insulating spacing therebetween. Thus, the electrical connecting portion prevents hot melting and provides better electrical connection reliability.