Abstract
An electrical connector for a glazing comprising a connector portion for connection to an electrical supply, and a button for soldering to a surface of the glazing, the button comprising a base portion adjacent, in use, to the surface of the glazing and an upper portion remote, in use, from the surface of the glazing, wherein the button comprises at least one solder-contacting surface, at least a portion of the solder-contacting surface curving from the base portion to the upper portion and defining a tapering solder cavity. A glazing comprising the electrical connector is also disclosed as is a method of soldering the electrical connector to a glazing.
Claims
1. An electrical connector for a glazing, the electrical connector comprising, a connector portion for connection to an electrical supply, and a button for soldering to a surface of the glazing, the button comprising a base portion adjacent, in use, to the surface of the glazing and an upper portion remote, in use, from the surface of the glazing, wherein the button comprises at least one solder-contacting surface, at least a portion of the solder-contacting surface curving from the base portion to the upper portion and defining a tapering solder cavity.
2. An electrical connector as claimed in claim 1, wherein the tapering solder cavity is shaped to draw molten solder into the tapering solder cavity.
3. An electrical connector as claimed in claim 1, wherein, in use, the portion of the solder-contacting surface cooperates with the surface of the glazing to define the tapering solder cavity.
4. An electrical connector as claimed in claim 1, wherein a first solder-contacting surface and a second solder-contacting surface cooperate to define the tapering solder cavity.
5. An electrical connector as claimed in claim 1, wherein the tapering solder cavity tapers out in a direction away from the surface of the glazing, in use.
6. An electrical connector as claimed in claim 1, wherein the electrical connector comprises steel, nickel, copper, brass, aluminium, or titanium.
7. An electrical connector as claimed in claim 1, further comprising a solder deposit adhered to the connector.
8. An electrical connector as claimed in claim 7, wherein the solder deposit is a substantially annular solder deposit.
9. An electrical connector as claimed in claim 1, wherein the connector portion comprises a spade connector portion.
10. An electrical connector as claimed in claim 1, wherein the button further comprises at least one spacer to space the base portion of the button from the surface of the glazing.
11. An electrical connector as claimed in claim 1, wherein at least a portion of the or each solder-contacting surface comprises a coating comprising copper, nickel, zinc, tin, silver, gold, or alloys or layers thereof.
12. A glazing comprising, a pane of glazing material, an electrically conductive layer on a surface of the pane, a solder deposit on the electrically conductive layer, and an electrical connector comprising at least one solder-contacting surface as claimed in claim 1 on the solder deposit.
13. A glazing as claimed in claim 12, wherein a fillet of solder extends into the solder cavity.
14. A glazing as claimed in claim 12, wherein the solder comprises lead-free solder.
15. A glazing as claimed in claim 12, wherein the solder wets the electrically conductive layer and/or the solder-contacting surface.
16. A glazing as claimed in claim 12, wherein the pane of glazing material comprises glass.
17. A glazing as claimed in claim 12, wherein the pane of glazing material comprises laminated glass.
18. A glazing as claimed in claim 17, wherein the laminated glass comprises a first ply of glass, a ply of interlayer material and a second ply of glass and the electrically conductive layer is on a surface of the first and/or the second glass ply.
19. A glazing as claimed in claim 12, wherein the glazing is a vehicle glazing.
20. A method of soldering an electrical connector to a glazing, the method comprising, providing a pane of glazing material with an electrically conductive layer on a surface of the pane, providing a solder deposit on the electrically conductive layer, providing an electrical connector as claimed in claim 1 on the solder deposit, and fusing the solder.
Description
(1) FIG. 1 illustrates a first connector according to the invention in (a) plan view, (b) in sectional view on A-A of (a), and (c) in sectional view on B-B of (a);
(2) FIG. 2 illustrates a second connector according to the invention in (a) plan view, (b) in sectional view on A-A of (a), and (c) in sectional view on B-B of (a);
(3) FIG. 3 illustrates a third connector according to the invention in (a) side view, (b) in sectional view on C-C of (a), and (c) in perspective view;
(4) FIG. 4 illustrates a fourth connector according to the invention in (a) side view, (b) in sectional view on E-E of (a), and (c) in perspective view;
(5) FIG. 5 illustrates a fifth connector according to the invention in (a) plan view, (b) in sectional view on G-G of (a), (c) in sectional view on H-H of (a), and (d) in perspective view;
(6) FIG. 6 illustrates a sixth connector according to the invention in (a) plan view, (b) in sectional view on I-I of (a), (c) in sectional view on J-J of (a), and (d) in perspective view;
(7) FIG. 7 illustrates a seventh connector according to the invention in (a) plan view, (b) in sectional view on K-K of (a), (c) in sectional view on L-L of (a), and (d) in perspective view;
(8) FIG. 8 illustrates an eighth connector according to the invention in (a) plan view, (b) in sectional view on A-A of (a), (c) in sectional view on B-B of (a), and (d) in perspective view;
(9) FIG. 9 illustrates a ninth connector according to the invention in (a) plan view, (b) in sectional view on A-A of (a), (c) in sectional view on B-B of (a), and (d) in perspective view;
(10) FIG. 10 is a schematic sectional side view of a connector soldered to a glazing according to the invention;
(11) FIG. 11 is a photograph of a section through a portion of a connector according to the invention after soldering to a substrate.
(12) In the Figures, the same reference numbers refer to the same or to corresponding features.
(13) FIG. 1 shows a first type of a connector 2 according to the present invention. The connector 2 comprises two main parts, a button 4 intended to be soldered on to the surface of a glazing (not shown, see FIG. 10) and a connector portion 6 in the form of a female spade connector, for connection to a cable (not shown) and hence to a device and/or a power supply. The connector 2 is formed of sheet metal, usually sheet steel (preferably mild steel because of its advantageous properties including coefficient of thermal expansion) or sheet copper or brass because of the beneficial wetting properties of these metals with solder. The solder contacting surfaces of the connector 2 are preferably plated with e.g. Cu, Ni, Ag in order to improve solder wetting of the surface still further. Usually, especially if the metal is steel, the metal will be plated with a single layer of Ni (or Ni/Cu), or with two layers: a layer of Ni (or Ni/Cu) on the steel and a layer of Ag on the Ni (or Ni/Cu).
(14) A section through the button 4 on A-A of FIG. 1(a) is shown in FIG. 1(b) and a section through B-B of FIG. 1(a) is shown in FIG. 1(c). As can be seen in FIGS. 1(b) and 1(c), the button 4 in cross section is in the shape of a truncated bell, with the skirt portion 7 of the button curving from the base portion 5 to the upper portion 9. The inner surface of the skirt portion 7 forms a solder-contacting surface 8 and, because of the curvature of the skirt portion 7, when the button 4 is on the surface of a glazing, the solder-contacting surface 8 defines a tapering solder cavity 10. The tapering solder cavity 10 acts, during soldering of the button on the surface of a glazing, because it tapers out away from the glazings (i.e. becomes wider further away from the glazing and more towards the centre of the button 4), to draw molten solder away from the periphery 3 of the button 4 and into the solder cavity 10. This, surprisingly, has the effect of significantly reducing the stress induced on the glazing during the soldering process reducing the chance of part (in particular, glass) breakage. It is thought that because of the taper of the solder cavity 10, and especially its curved taper, capillary action and thermal expansion of the molten solder both act to draw the molten solder into the solder cavity 10.
(15) FIG. 2 shows a second type of connector according to the invention. The connector 2 in FIG. 2 is of generally similar form to the connector 2 of FIG. 1 and will not be described in detail. The connector portion 6 in the form of a spade connector of FIG. 2 is generally wider in relation to the button 4 to accommodate different cables to those suitable for connection to the connector 2 of FIG. 1. The skirt portion 7 of the button 4 of the connector 2 shown in FIG. 2 is formed of thicker sheet metal to modify the thermal and strength properties of the button 4.
(16) FIG. 3 shows a third type of a connector 12 according to the present invention. The connector 12 is of a different form to the connectors of FIGS. 1 and 2. The connector 12 comprises a button 14 intended to be soldered to the surface of a glazing (not shown). The connector 12 is of generally cylindrical form. The inside of the connector 12 forms a hollow portion 26 which may act as a connection portion by insertion of a cable connector of suitable form into the hollow portion 26. After insertion of such a cable connector the hollow portion 26 may retain the cable connector by interference and/or resilience (e.g. a snap-action connector), by adhesive or may be crimped or soldered to fix the cable connector in position. The connector 12 has a base plate 16 and protruding from the base plate 16 there are three spacers 18 which act, when the connector is on the surface of a glazing, to space the button 14 an appropriate distance above the glazing surface to enable solder to flow under the button consistently and evenly. The spacers 18 may space the button 14 a distance of from 0.1 mm to 2 mm above the glazing surface, preferably about 0.25 mm above the glazing surface.
(17) The connector 12 is formed of sheet metal, usually sheet steel (preferably mild steel because of its advantageous coefficient of thermal expansion) or sheet copper because of the beneficial wetting properties of these metals with solder. The solder contacting surfaces of the connector 12 are preferably plated with e.g. Cu, Ni, Ag in order to improve solder wetting of the surface still further.
(18) A section through the button 14 on C-C of FIG. 3(a) is shown in FIG. 3(b). As can be seen in FIG. 3(b), the button 14 in cross section is seen to be formed of the sheet metal curved and folded to form a first sheet portion 20 and a second sheet portion 24 and an annular tapering solder cavity 22 between the first sheet portion 20 and a second sheet portion 24. The solder cavity 22 is narrow towards the base plate 16 of the button 14, and tapers outwards in the direction away from the base plate 16. The inner surfaces of the first sheet portion 20 and a second sheet portion 24 in the solder cavity 22 form a first solder-contacting surface 23 and a second solder contacting surface 25 respectively. The tapering solder cavity 22 acts during soldering of the button 14 on to the surface of a glazing, because it tapers out away from the glazings (i.e. becomes wider further away from the glazing), to draw molten solder away from the periphery of the base plate 16 and into the solder cavity 22. This, surprisingly, has the effect of significantly reducing the stress induced on the glazing during the soldering process reducing the chance of part (in particular, glass) breakage. It is thought that because of the taper of the solder cavity 22, and especially the curving first solder contacting surface 23 and second solder contacting surface 25 where the sheet metal is folded, capillary action and thermal expansion of the molten solder both act to draw the molten solder into the solder cavity 22.
(19) FIG. 3(c) shows a perspective view of the connector 12 showing the button 14, hollow portion 26, base plate 16 and spacer 18.
(20) FIG. 4 shows a connector 31 of generally similar form to the connector 12 of FIG. 3 and similar parts will not be described in detail. The connector 31 comprises a button 35 with a hollow portion 36 and a base portion 37. The connector 31 differs from connector 12 of FIG. 3 in that the base portion 37 of FIG. 4 extends outwardly from the circumference of the button 35 and is designed to contact the glazing surface. As seen in FIG. 4(b), which is a section on E-E of FIG. 4(a), the base portion acts as a skirt with the outer part of the skirt intended to sit flush on the glazing surface and acting as an elevation spacer 39 to provide a recess inside the skirt for solder to contact the button 35. As in FIG. 3, the connector 31 is formed of a curved, folded metal sheet, forming a first sheet portion 30 and a second sheet portion 34 defining an annular solder cavity 32.
(21) FIG. 4(c) shows a perspective view of the connector 31 showing the button 35, hollow portion 36, and base portion 16.
(22) FIG. 5 shows a fourth type of a connector 42 according to the present invention. The connector 42 is of a folded type generally as shown in FIGS. 3 and 4, but in this case comprises a button 44 intended to be soldered to a glazing surface (not shown, see FIG. 10) and a connector portion 46 in the form of a female spade connector, for connection to a cable (not shown) and hence a device and/or power supply. The connector 42 is formed of sheet metal, usually sheet steel (preferably mild steel because of its advantageous coefficient of thermal expansion) or sheet copper because of the beneficial wetting properties of these metals with solder. The solder contacting surfaces of the connector 42 are preferably plated with e.g. Cu, Ni, Ag in order to improve solder wetting of the surface still further. A section through the button 44 on G-G of FIG. 5(a) is shown in FIG. 5(b). As can be seen in FIG. 5(b), the button 44 in cross section is of generally cylindrical form and is formed of sheet metal, curved and folded to form a first sheet portion 47 and a second sheet portion 49 and an annular tapering solder cavity 48 between the first sheet portion 47 and a second sheet portion 49. The solder cavity 48 is narrow towards the base of the button 44, and tapers outwards (thus, widening) in the direction away from the base. The inner surfaces of the first sheet portion 47 the second sheet portion 49 in the solder cavity 48 form a first and second solder-contacting surface respectively. The tapering solder cavity 48 acts, during soldering of the button 44 on to the surface of a glazing to draw molten solder away from the periphery of the button 44 and into the solder cavity 48. This, surprisingly, has the effect of significantly reducing the stress induced on the glazing during the soldering process reducing the chance of part, especially glass, breakage. It is thought that because of the taper of the solder cavity 48, and especially the curving first and solder contacting surfaces where the sheet metal is folded, capillary action and thermal expansion of the molten solder both act to draw the molten solder into the solder cavity 48.
(23) FIG. 5(d) shows a perspective view of the connector 42 showing the button 44, hollow portion 50, connector portion 46 and one of the three spacers 52 protruding from the base of the button 44 which act, when the button 44 is on the surface of a glazing, to space the button 44 an appropriate distance above the glazing surface to enable solder to flow under the button consistently and evenly. The spacers 52 may space the button 44 from 0.1 mm to 2 mm above the glazing surface, preferably about 0.25 mm above the glazing surface.
(24) FIGS. 6, 7, 8 and 9 show respectively sixth, seventh, eighth, and ninth types of connectors according to the invention. The connectors in FIGS. 6 to 9 are generally similar in form to the connector 42 of FIG. 5 and will not be described in detail. In the connectors 42 of FIGS. 6 to 10, the relative size of the buttons 44 and connector portions 46 varies and, in FIG. 9, the connector portion 46 is in the form of a male spade connector.
(25) FIG. 10 illustrates schematically a connector 102 according to the invention, soldered on to a glazing surface. The connector 102 comprises a button portion 104 and a spade connector 106. The button portion 104 is soldered on to the electrically conductive coating 110 (usually comprising silver particles in a glass frit) adhered to the surface of a glass substrate 108. The glass substrate 108 may be a single sheet of glass. Alternatively, the glass substrate 108 may be a laminated glass substrate comprising a first glass ply, an interlayer material (preferably of polyvinyl butyral, PVB) and a second glass ply. The surface to which the electrically conductive coating 110 is adhered is preferably the surface of the first glass ply or second glass ply. Because of the curved solder contacting portion 112 of the button portion 104, solder, when molten, is drawn (it is thought, without wishing to be bound, by capillary action and/or thermal expansion) into the solder cavity 113 defined by the solder contacting portion 112 and electrically conductive coating 110 surface. When solidified, the solder forms a solder fillet 114 in the solder cavity 113.
(26) FIG. 11 is a photograph of a section through the button part of a connector on a substrate 116, the connector being generally as illustrated in FIGS. 3 to 9. The photograph shows the connector after soldering with folded first sheet portion 117 and second sheet portion 115 defining a tapering solder cavity 113 containing a solder fillet 114 which was drawn up as molten solder into the solder cavity 113 by capillary action and/or thermal expansion during soldering.
REFERENCE NUMERALS
(27) 2 connector 3 periphery of button 4 button 5 base portion of button 6 connector portion 7 skirt portion 8 solder-contacting surface 9 upper portion of button 10 tapering solder cavity 12 connector 14 button 16 base plate 18 spacer 20 first sheet portion 22 solder cavity 23 first solder contacting surface 24 second sheet portion 25 second solder contacting surface 26 hollow portion 30 first sheet portion 31 connector 32 solder cavity 34 second sheet portion 35 button 36 hollow portion 37 base portion 39 elevation spacer 42 connector 44 button 46 connection portion 47 first sheet portion 48 solder cavity 49 second sheet portion 50 hollow portion 52 spacer 102 connector 104 button portion 106 spade connector 108 glass substrate 110 electrically conductive coating 112 solder contacting portion 113 solder cavity 114 solder fillet 115 second sheet portion 116 substrate 117 first sheet portion
