FIELD OF THE INVENTION

[0001] The present invention relates to an electrical connector for glass applications especially relevant in electrical assemblies on the surface of glass. More specifically the present invention relates to an electrical connector used for carrying electrical current to a pane comprising an electrically conductive element comprising a metallic layer or wire. Electrical connector and conductive layer are joined together by a solder material or a conductive adhesive or a glue. Even more the present invention relates specifically to an electrical connector for a pane of a vehicle. Furthermore specifically, the subject-matter of the invention relates to an electrical connector that is useful to transfer electrical energy to an electrical device of a vehicle, such as but not limited to defogger, defroster, heating grid, antenna, camera, sensors and etc.

BACKGROUND OF THE INVENTION

[0002] Electrical connectors are known in the art for use on glass surfaces, especially in vehicles. The connectors are assembled to and in electrical communication with an electrically conductive layer or wire provided on the glass surface for transferring electrical energy to the electrical device. More specifically, the conductive layers, which generally include silver, are screen printed or deposited on a substrate that is formed from glass, such as a backlite, sidelite, roof or windshield of a vehicle but not limited to such examples. The conductive layers typically extend horizontally across the window panes. The conductive layers can also form electrical devices such as in general defoggers, defrosters, heating grids and antennas and etc.

[0003] The electrical assemblies in vehicles generally experiences harsh conditions on the road. Automotive electronics commonly are exposed to rapid temperature changes as low as - 50 °C to as high as + 120 °C depending on the seasons or continents. The differences in coefficients of thermal expansion (CTE) between different components of the electrical assembly result in residual stresses built up during the temperature fluctuations. Such stresses cause cracking or other damage to the glass substrates or malfunctioning of the electrical devices such as defoggers, defrosters, and antennas because of the connector disconnecting from the conductive element. The residual stresses may also arise from other source such as fatigue or vibrational loads in the service of a vehicle.

[0004] These tough conditions are generally simulated during the aging tests and standards for the required conditions defined by authorities, such as pull-off force for glass-metal junctions, the pull-off force is defined as the force required for the connector to break-off from the glass substrate or from the conductive element. The joining connector not only allows transfer of current from cable to conductive element but also maintains the electrical joint integrity during thermal fluctuations or mechanical loads or vibrational loads. It is a major problem that connectors with small surfaces like disks or plates fall off after aging test or cannot withhold the required strength. Apart from the soldering material or the adhesive used for the fixing of the connector to the conductive element, shape and size of the connector also has importance on the integrity of the joint. Thus to achieve a strong connection, connectors with relatively high contact areas needs to be used which occupy a significant space for a connection. However, with rapid growth in the demand for vehicle electronics, more and more connections needed for connections to vehicle glazing and the said requirements from the regulations limit manufacturers.

[0005] Alternately connector materials used in the electrical assemblies can be changed to improve the strength of the joint by minimizing thermal and mechanical stresses. Conventional connector material such as copper exhibits superior electrical conductivity, thermal conductivity and low specific heat values, but possess high CTE (16.7 x 10’ ⁶ /°C) compared to glass which make the joint highly susceptible to stress. Materials with CTE values close to glass have been researched by the manufacturers over the past years.

[0006] Although various materials proposed as connector replacement to copper for use in the window panes of vehicles to improve the strength of the joint, such developments have little applicability to electrical connector technology. For example, European Patent No. EP2708091 also discloses a laminated pane for a vehicle including an electrical connection element provided on the glass panes by soldering through a conductive layer. The electrical connection element includes a layered structure that may include chromium-containing steel.

[0007] For example, European Patent No. EP1657964 and EP1942703 also disclose a laminated pane for a vehicle including an electrical connector provided on the glass panes. The electrical connector includes a layered structure that may include titanium to provide rigidity to the electrical connector.

[0008] For example, European Patent No. EP2594109 also discloses a laminated pane for a vehicle including an electrical connection element provided on the glass panes by soldering through a conductive layer. The electrical connection element includes a dent of which the soldering material is thickened in the region of the dent.

[0009] For example, European Patent No. EP1554773 also discloses a laminated pane for a vehicle including an electrical connection element provided on the glass panes. The electrical connection element includes a plug for a flat cable of which comprises number of conductors insulated from one another.

[0010] For example, European Patent No. EP2923528 discloses a laminated pane for a vehicle including an electrical connection element provided on the glass panes by soldering through a conductive layer. The connector comprises a bridge portion made of a material different than the material of the contact elements.

[0011] For example, United States Patent No. US10873143 discloses a laminated pane for a vehicle including an electrical connection element provided on the glass panes by soldering through a conductive layer. The connector comprises a bridge portion which fixed to the contact elements via rivets.

[0012] In the state of the art, United States Patent Application No. US20160240935, discloses a connector to be used with lead-free solder that an adhesive containing portion needed for the connector to provide necessary mechanical strength for the connection although the connector may comprise two conductive contact elements.

[0013] In the state of the art, United States Patent Application No. US20070029301 , discloses a connector comprising two non-isolated conductive contact elements and a resin material is potted over the connector to compensate the mechanical stress occurred during soldering.

[0014] Although the problem of establishing a rigid connection between the conductive element and the connector has been partially solved in cited prior art, there is still a need for a small-sized connector itself for a better utilization of the glass surface of which also enables more connections on glass therefore more devices connected to glass surface. [0015] Thus, there remains a clear need of finding an appropriate replacement to conventional connectors for a more stable, steady and small-scale alternative. Underlying motivation is to improve the pull-off force between the connector and the substrate from decreasing due to environmental effects resulting from changes in temperature, and further operate without degradation for a long lasting operation, and further ability to connect more connections to the glass substrate, and further facilitate more applications for vehicles by improving utilization efficiency.

SUMMARY OF THE INVENTION

[0016] The present invention provides an electrical connector for a pane. The pane includes a substrate formed from glass. The present invention also provides the pane including the electrical connector and a vehicle including the pane. The present invention relates, in another aspect, to usage of a such connector in glass applications. The present invention also relates, in another aspect, to utilization of a such pane in automotive industry. An electrical connector and an electrically conductive element such as a layer or a wire provided on the substrate may form an electrical device or at least some part of the electrical device. The connector is operatively connected to and in electrical communication with the conductive element for transferring electrical energy to the electrical device.

[0017] The connector of the present invention is suitable for a pane comprising a substrate formed from glass and an electrically conductive element provided on at least a portion of the substrate and the connector is to be attached or connected to the conductive element to be in electrical communication, and the connector comprises at least two contact elements which are to be fixed to the conductive element on glass surface and enabling the current passing through from cables to conductive element, and a bridge element connecting the contact elements together and also blocking current passing from one contact element to other. Depending on the intended applications, the bridge element connects the contact elements together in a rigid manner or in a ductile way.

[0018] The connector of the present invention provides at least two electrical connections on the glass surface by simply one connector. Connection cables are fixed to the contact elements respectively, fixation can be achieved by crimping or welding or soldering or any other method thereof. The bridge element ties at least two contact elements together that the connector has the strength of a connector with large contact area but with at least two connections thanks to the non-conductive nature of the bridge element. That allows the pulling off force for one connection to double at least without increasing the contact area or changing the material of the contact element, i.e. , the force required for the connector to come off is doubled at least. That also allows the better utilization of the glass surfaces by enabling more connections in a predetermined area. However, as will be detailed later on, the connector of the present invention can also be used where one electrical connection is needed on the glass surface.

[0019] The present invention also relates to the structural and electrical properties of a connector, more specifically materials that made of the bridge element of the connector and even more specifically connectors utilized on glass surfaces. The present invention relates, in another aspect, to usage of such electrical connectors on glass panes. The present invention provides a connector which can withstand to high mechanical stress and large thermal fluctuations. The proposed connectors are superior in structural properties such as strength and small size and enabling more connections. As a result of electrical insulation between the contact elements, a considerable reduction of the overall size of the connector for at least two connections to the glass surface and also improvement of the overall mechanical strength of the connector in operation due to environmental effects. Furthermore, the present invention provides a connector more stable in wide range of conditions, more rigidity and more flexural strength to the joint assembly of the substrate with electrically conductive element and the connector. The connector of the present invention finds itself a wide range of applications like antennas requiring at least 2 contacts or glass break sensors used in vehicles or camera heating applications which require more than one contact to the glass substrate. In addition to all above, the present invention provides a connector with said properties in a cost efficient way.

[0020] The present invention further concerns providing a unique (tailor-made) solution for glass substrates in automotive industry such as vehicle comprising such an assembly comprising the pane, electrical device and the connector not to mechanically fail abruptly. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The invention will now be described further, byway of examples, with reference to the accompanying drawings, wherein like reference numerals refer to like elements in the various figures. These examples are provided by way of illustration and not of limitation. The drawings are a schematic representation and not true to scale. The drawings do not restrict the invention in any way. More advantages will be explained with examples.

[0022] Fig.1 illustrates the contact elements fixed to one conductive element, while Fig.2 illustrates the contact elements are fixed to two different conductive elements. Fig.3, Fig.4 and Fig.5 illustrates different embodiments for different fixation of cables. Fig.6, Fig.7 and Fig.8 illustrates a top view of different variations of connectors.

[0023] The elements illustrated in the figures are numbered as follows:

1 . Connector

2. Pane

3. Substrate

4. Conductive element

11 . Contact element

12. Bridge element

13. Leg portion

14. Crimp

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0024] The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto but only by the claims.

[0025] While some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

[0026] As used herein, spatial or directional terms, such as "inner", "outer", "above", "below", "top", "bottom", and the like, relate to the invention as it is shown in the drawing figures. However, it is to be understood that the invention can assume various alternative orientations and, accordingly, such terms are not to be considered as limiting. Further, all numbers expressing dimensions, physical characteristics, processing parameters, quantities of ingredients, reaction conditions, and the like, used in the specification and claims are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical values set forth in the following specification and claims are approximations that can vary depending upon the desired properties sought to be obtained by the present invention. In the following description, unless otherwise specified, expression “substantially” mean to within 10%, preferably to within 5%.

[0027] Moreover, all ranges disclosed herein are to be understood to be inclusive of the beginning and ending range values and to encompass any and all subranges subsumed therein. For example, a stated range of "1 to 10" should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g. 1 to 6.1 , and ending with a maximum value of 10 or less, e.g., 5.5 to 10. Further, as used herein, the terms "deposited over" or "provided over" mean deposited or provided on but not necessarily in surface contact with. For example, a coating "deposited over" a substrate does not preclude the presence of one or more other coating films of the same or different composition located between the deposited coating and the substrate.

[0028] Where the term “comprising” is used in the present description and claims, it does not exclude other elements or steps. Where an indefinite or definite article is used when referring to a singular noun e.g. "a" or "an", "the", this includes a plural of that noun unless something else is specifically stated. In this document, "configured to (or set to)" may be interchangeably used in hardware and software with, for example, "appropriate to", "having a capability to", "changed to", "made to", "capable of", or "designed to" according to a situation. In any situation, an expression "device configured to do" may mean that the device "can do" together with another device or component.

[0029] Furthermore, the terms first, second and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequence, either temporally, spatially, in ranking or in any other manner. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein. When it is described that a constituent element (e.g., a first constituent element) is "(functionally or communicatively) coupled to" or is "connected to" another constituent element (e.g., a second constituent element), it should be understood that the constituent element may be directly connected to the another constituent element or may be connected to the another constituent element through another constituent element (e.g., a third constituent element).

[0030] “connector” and “electrical connector” and “electrically conductive connector” are used interchangeably throughout the text, “pane” and “window pane” and “glass pane” and “glazing” and “laminated glazing” are used interchangeably throughout the text, “in electrical communication” or “in an electrically communicated manner” throughout the text is to be understood as electrical current can flow between the mentioned two elements regardless of having an actual physical contact.

[0031] Referring the figures, wherein like numerals indicate like or corresponding parts throughout the several views, a pane (2) is generally shown per se and it can be utilized on a vehicle or alike. The pane (2) comprises a substrate (3) preferably formed from glass. The glass substrate (3) is further defined as an automotive glass but not limited to. In a preferred embodiment, the automotive glass is further defined as soda lime silica glass, which is well known for use in window panes (2) of vehicles. However, it is to be appreciated that the glass may be any type of glass composition or in any shape that is known in the art like the borosilicate, quartz, flat or curved or float or etc.

[0032] The present invention proposes a wired connection to a pane (2) formed from glass to be utilized in a vehicle and more preferably on a laminated glazing but not limited to. A vehicle should be understood as any conveyor that transfers anything from point a to point b which includes any land, air or sea vehicles like car, van, lorry, motorbike, bus, tram, train, drone, airplane, helicopter and the like.

[0033] A laminated glazing refers to at least two sheets of glass being laminated with an interlayer. The sheets of glass can be made of (mineral) glass, more specifically a silica-based glass, such as soda-lime-silica, alumino-silicate or boro-silicate type glass. The interlayer is usually made of polyvinyl butyral (PVB) or ethylene-vinyl acetate (EVA). However, as mentioned above the present invention is not limited to laminated glazings.

[0034] An electrically conductive element (4) is applied across a region of the substrate (3) such that the conductive element (4) is on at least a portion of the substrate (3). Preferably, the conductive element (4) includes silver, however, it is to be appreciated that other conductive metals like copper may also be suitable for the conductive element (4). The conductive element (4) may be formed on a surface of the glass sheet by sintering a silver paste containing a silver powder and a glass frit and which can also be deposited or painted or printed on the pane (2) surface or by any method as long as providing an electrically conductive element (4) on the surface of the substrate (3). The electrically conductive element (4) may be visible on the window pane (2) and typically comprises lines that extend horizontally across the window pane (2) but also it can be transparent electrically conductive element (4). The conductive element (4) is preferably part of an electrical device (7) like a defogger, defroster, antenna, heating grid, sensors, camera heating elements, glass break sensors or combination thereof. However, the conductive element (4) may serve any function known in the art for such conductive elements (4).

[0035] In another embodiment of the present invention, the substrate (3) material is an amorphous substance in the form of flat long plate or curved glass sheet or glass sheet coated with electrically conductive element (4) as on one or two of its surfaces to facilitate an electrical joint and an electrical device but not limited to.

[0036] In other embodiments the conductive element (4) in the present invention may be screen printed or deposited by physical or chemical vapor deposition techniques or simply painted on the surface(s) of the substrate (3). In some other embodiments, the conductive element (4) may comprise one or more of the following materials such as but not limited to C, Graphene, Ag, Au, Cu, Ni, Al, Ti, Or, Fe, V or W.

[0037] Referring to figures 1 to 2, an electrical connector (1 ) is operatively connected to and in electrical communication with the conductive element (4), specifically in Fig.2 the connector is connected to two different conductive elements (4). Together, the conductive element (4) and the connector (1 ) may form an electrical device or some part of it. The connector (1 ) is aimed to transfer electric current or a signal between the electrical device and the conductive element (4) provided on the substrate (3). The current or signal is carried over electrically conductive cables (not shown) which are in electrical communication with the connector (1 ) of the present invention.

[0038] In one embodiment of the present invention, a layer of solder material is bonded to the electrical connector (1 ). A layer of solder material preferably lead-free is bonded to the layer of solderable metal and the conductive element (4), with the connector (1 ) and the conductive element (4) in electrical communication through the layer of solder metal and the layer of solder material. The solder material solders the electrically connector (1 ) to the electrically conductive element (4). The solder material can be made of lead alloys or lead-free alloys depending of the legislation and/or the thermal expansion needed between the substrate element and the electrically conductive structure.

[0039] In different embodiments of the present invention, the solder material could be replaced by a conductive adhesive or glue that the connector (1 ) is attached to the conductive element (4) by a conductive glue or adhesive such that the connector (1 ) is fixed to the conductive element (4) in an electrically communicated manner.

[0040] The connector (1 ) of the present invention is for a pane (2) comprising a substrate (3) formed from glass and a conductive element (4) provided on at least a portion of the substrate (3) and the connector (1 ) is to be connected to the conductive element (4) in electrical communication and wherein the connector (1 ) comprises at least two electrically conductive contact elements (11 ) to be fixed to at least one conductive element (4) and the contact elements (11 ) are connected to each other via a bridge element (12), wherein the bridge element (12) is electrically non-conductive, i.e., the conductive contact elements (11 ) are electrically isolated from each other. The connector (1 ) of the present invention, therefore, is a single piece connector with two isolated contact elements (11 ). The contact elements (11 ) are fixed to at least one conductive element (4) in electrically communicated way. In a preferred embodiment, each contact element (11 ) is fixed to a separate conductive element (4) to utilize more electrical connections by just one connector (1 ) as exemplified in FIG. 2. Cables from the electrical device are fixed to the contact elements (11 ) respectively. In some other embodiments, contact element (11 ) might have a crimp (14) to facilitate the cable connection.

[0041] The bridge element (12) holds the contact elements (11 ) together by being fixed to each contact element (11 ) in a non-conductive manner, i.e., the bridge element (12) electrically isolates the contact elements (11 ) while keeping them together in place as a single piece bridge connector. At least two contact elements (11 ), therefore, acts separately and independently in terms of electrical connections i.e., like two different connectors and acts as one single element in terms of structure. The connector (1 ) being single piece provides rigidity and strength that pull-off force for the cable is in the range required by the regulations, i.e., the force for the connector (1 ) to be detached from the conductive element (4) or the glass substrate (3) is in the range required by the regulations. The bridge element (12) can be made from any insulator material in a rigid way or in a flexible/elastic/ductile way depending on the intended application assuring the electrical isolation of the contact elements (11 ). Since the contact elements (11 ) provides both the electrical and mechanical connection to the conductive element(s) (4), and the cables are directly connects to the contact elements (11 ), no other means needed for mechanical connection of the connector (1 ). Preferably, the electrically non-conductive bridge element (12) is not in-contact, i.e., mechanically attached with the conductive element (4) or the cables.

[0042] In other embodiments of the present invention, the bridge element (12) is made of plastic material or thermoplastic polyurethane (TPU) or thermoplastic elastomer (TPE) or semi-aromatic polyarylamides (PARA) or from polymer-based material, but not limited to, the material of the bridge element (12) can be any non-conductive material having higher tensile strength, preferably as much as or close to the tensile strength of the material of the contact elements (11 ) and with preferably lower glass transition temperature for cold conditions. The plastic-based material can be made of a thermoplastic material, polyurethane (Pll), polyamide, acrylic, polycarbonate, polyoxymethylene (POM), Polystyrene (PS), Acrylonitrile butadiene styrene (ABS), Polypropylene (PP), Polyethylene (PE), thermoplastic polyurethane (TPU), thermoplastic rubber (TPR), an epoxy, an acrylic resin or any suitable material preferably to be injected into a mold.

[0043] In other embodiments of the present invention, the thermoplastic can be reinforced with fibers, such as glass , carbon, aramid fibers to achieve more rigidity for the bridge element (12).

[0044] In some other embodiments of the present invention, the bridge element (12) is over molded over the contact elements (11 ). Over molding can be achieved via insert molding by keeping the contact elements (11 ) as substrate or in any other method for over molding. As mentioned in above embodiments, when the bridge element (12) and the contact elements (11 ) are attached via over molding, the material of the bridge element (12) is chosen from any suitable material to be injected into a mold providing the material is electrically non-conductive. It should be understood that the connector (1 ) is manufactured via overmolding process prior to the attachment onto the conductive element (4).

[0045] In a version of this embodiment, the contact element (11 ) comprises a leg portion (13) for over-molding process to facilitate a rigid connection between the contact elements (11 ) and the bridge element (12) as exemplified in FIG. 3 - 8. In another embodiment, the leg portion (13) is T-shaped to provide a successful mechanical interlock with the bridge element (12). Thus, the leg portion (13) is part of the contact element (11 ).

[0046] The shape of the contact elements (11 ) can be disk-shaped or rectangularshaped or oval-shaped depending on the intended applications in different embodiments. In some other embodiments, the shape of the contact element (11 ) is independent from the leg portion (13), i.e. for a disk-shaped contact element (11 ), the leg portion (13) protrudes from the disk shape. For the sake of the nature of the invention, the shape of the contact elements (11 ) are not utmost important.

[0047] In other embodiments of the present invention, the contact elements (11 ) are soldered or adhered to the conductive element (4). In various embodiments of the present invention, cables from the electrical device such as the amplifier or alike, are fixed to the connector (1 ), especially to the contact elements (11 ) preferably via a crimp (14) from a top surface of the contact element (11 ) but not limited to, the connection can also be done via any other conventional methods like spot welding, ultrasonic bonding or regular soldering or gluing conductively or any other method, i.e., at least one contact element (11 ) comprises a means to crimp or solder or weld or glue conductively a cable. The said top surface can be on the same axis with the bottom surface of the contact element (11 ) where the contact element (11 ) is attached to the conductive element (4) as exemplified in figure 3. In different embodiments where the contact element (11 ) is attached to the conductive element (4) via automated soldering robot/machine, cables then can be fixed to the contact element (11 ) on the leg portion (13) or in proximity of the bridge element (12) as exemplified in figure 4 and figure 5. [0048] The present invention also proposes a pane (2) comprising a substrate (3) formed from glass and an electrically conductive element (4) provided on at least a portion of the substrate (3) and a connector (1 ) described above in detail is attached to the conductive element (4) so as to be in electrical communication with the conductive element (4). The conductive element (4) on the substrate (3) is equipped with conductive wires and/or two dimensional conductive layers. The conductive wires are placed vertically, but they can also be placed horizontally or along any other orientation over the substrate (3).

[0049] In different versions of this embodiment, the substrate (3) is glass which can be made of (mineral) glass, more specifically a silica-based glass, such as soda-lime- silica, alumino-silicate or boro-silicate type glass or other material or shape types like quartz, flat or curved or float or etc.

[0050] In another versions of this embodiment, the conductive element (4) provided on the glass substrate (3) may comprise one or more of the following materials such as but not limited to C, Graphene, Ag, Au, Cu, Ni, Al, Ti, Or, Fe, V or W.

[0051] The present invention also proposes a vehicle comprising at least one pane (2) as described previously. In a preferred embodiment, the pane (2) is a windshield or a sidelite or a backlite or a roof of a vehicle or any surface where glass is utilized. The present invention also proposes a vehicle comprising at least one assembly as described previously.

[0052] The present invention also proposes the usage of an electrical connector (1 ) with an insulated bridge element (12) as described above in detail as current/signal carrier to any electrically conductive element (4) provided on glass substrate (3) for panes (2). As described above in detail that usage of a such connector (1 ) on glass surfaces provides better mechanical strength which facilities less mechanical and thermal stress on glass surface, i.e., long lasting operation without falling off or cracking of or any other damage to glass or the electrical device.

[0053] The present invention also proposes the usage of a such pane (2) described above in detail in and/or for automotive applications. Applications of such a pane (2) is not limited to just automotive industry, the pane (2) can be used for internal and external windows of buildings and also for displays like TVs, information boards.

[0054] With the connector (1 ) of the present invention, an improvement for the pulling off force for an electrical connector (1 ) is achieved on the surface of a pane (2) comprising a substrate (3) formed from glass, therefore the connector (1 ) will separate from the conductive element (4) or from the glass substrate (3) with a more force than the force defined in the standards by the regulation. The connector (1 ) of the present invention provides better utilization of the substrate (3) and more connections through the conductive element (4) in addition to an adequate amount of pulling off force of cabling to the substrate (3) of the pane (2), that makes compatibility for a wide range of applications on glass surfaces. In general, the connector (1 ) of the present invention is suitable to be used in applications on glass where high pulling-off force requested, more specifically low current applications with high requested pull-off force, even more specifically when multiple connections required to the glass substrate (3).

[0055] While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. The foregoing description details certain embodiments of the invention. It will be appreciated, however, that no matter how detailed the foregoing appears in text, the invention may be practiced in many ways. The invention is not limited to the disclosed embodiments.