CN101443960A - 电连接器 - Google Patents

电连接器 Download PDF

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CN101443960A
CN101443960A CN200780017259.5A CN200780017259A CN101443960A CN 101443960 A CN101443960 A CN 101443960A CN 200780017259 A CN200780017259 A CN 200780017259A CN 101443960 A CN101443960 A CN 101443960A
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vehicle window
conductive component
connector
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CN101443960B (zh
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M·里昂
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Pilkington Group Ltd
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    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
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    • B23K35/24—Selection of soldering or welding materials proper
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    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
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    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
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    • H01R12/712—Coupling devices for rigid printing circuits or like structures co-operating with the surface of the printed circuit or with a coupling device exclusively provided on the surface of the printed circuit
    • H01R12/714—Coupling devices for rigid printing circuits or like structures co-operating with the surface of the printed circuit or with a coupling device exclusively provided on the surface of the printed circuit with contacts abutting directly the printed circuit; Button contacts therefore provided on the printed circuit
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    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
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    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
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    • H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
    • H05K3/32—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits
    • H05K3/34—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits by soldering
    • H05K3/341—Surface mounted components

Abstract

公开了一种改进了的在车窗中使用的电连接器。车窗优选地包括具有第一导电部件安装在其上的一层车窗材料，和通过焊料接合到所述第一导电部件的第二导电部件。所述第二导电部件包括由桥接部分链接的第一和第二连接器脚，所述桥接部分处于在每个所述连接器脚之上的高度h处，并且每个所述脚包括至少一个具有高度(d)的突起。其中选择t或h中的至少一个以最大化所述第二导电部件和所述第一导电部件之间的附着力。优选地，所述车窗是汽车车窗。

Description

电连接器
技术领域
本发明涉及一种用于汽车车窗的电连接器。
背景技术
多种电连接器在汽车车窗工业中被普遍使用。例如，丁字片连接器可以用于把导电电路、如印刷在一层玻璃的表面上的电路或者在夹层车窗中固定的一排电线连接到车辆的线束。这样的电路通常作为加热电路使用，以助于去雾、去冰或者用作天线电路。丁字片连接器被焊接到称作汇流条的导电衬底，其可以在玻璃片的表面上直接提供，或者全部或部分地在玻璃上地烧结了的、所印刷的带上面提供，其被称为装饰边。汇流条通常使用含银油墨印刷。常规地，用于连接汇流条和连接器的焊料含有铅。然而，铅已知是有毒的，并且在汽车工业中使用无铅焊料有着迫切的要求，例如，如在WO2004/068643中所描述的。WO2004/068643公开了基于锡的焊料(直至90％重量的锡)，包括从铋或者铟中所选择的机械应力改良剂。这种焊料也可包含银和/或铜。
然而，使用无铅焊料的一个缺点是连接器和汇流条之间的附着力可能不像由含铅的焊料给出的那样高。对此的一个解决方案是另外使用一种粘合剂以承受在连接器上的机械负荷，如在EP1 256 261中的那样。
即使使用附加粘合剂的方法，连接器和汇流条之间由于焊接引起的附着力将随着时间由于环境条件、如极端的温度和湿度而降低。一旦连接器和汇流条之间的接合开始降低，附着力减小并且连接器可能变松或者直接与汇流条脱离。此外，当接合恶化时，能达到的电连接的质量可能变差。如果在连接器与汇流条连接的表面存在由于空气气泡或者碎屑引起的附着力差的区域，这种降低可能更加快速。因此，为了提高接合的可靠性，不仅必须考虑粘合剂和焊料选择，还应考虑处理技术和条件。
因此需要能够找到一种替代方式以当暴露在各种环境条件下时提高连接器和汇流条之间的接合的可靠性，其不依赖于材料选择或者特殊处理技术，但是其有助于阻止粘合剂和电连接的降低。
发明内容
本发明的目的在于通过提供一种包括一层车窗材料的车窗来解决这些问题，所述车窗材料具有安装在其上的第一导电部件和通过无铅焊料连接到第一导电部件上的第二导电部件，，第二导电部件包括由桥接部分链接的第一和第二连接器脚，桥接部分在每个连接器脚之上的高度h处，每个脚包括至少一个具有高度d的突起，其中选择h或d中的至少一个以最大化第二导电部件和第一导电部件之间的附着力。
通过优化连接器的设计，第一和第二导电部件之间的结合的可靠性提高了，而不需要提供附加的粘合剂或者执行复杂的处理步骤。
优选地，h是在1.0mm到小于或等于5.0mm的范围内。优选地，d是在0.00mm到1.0mm的范围内。更加优选地，d是在0.3mm到0.75mm的范围内。
当第一导电部件被置于平面浮法玻璃时，第二导电部件被焊接到其上，选择h或d中的至少一个使得移除第二导电部件所需的平均负荷优选地大于20kg。
更加优选地，选择h和d以提高第二导电部件和第一导电部件之间的附着力。可以选择h和d以提高在50℃和95％相对湿度的条件下14天之后第二导电部件和第一导电部件之间的附着力。
第二导电部件可以由铜制成。第一导电部件可以是汇流条。该层车窗材料的表面可以使用烧结油墨边围绕它的周边印刷。在这种情况下，第一导电部件的至少一部分可以在烧结油墨边上提供。
优选地，第二导电部件是丁字片连接器。优选地，焊料是无铅焊料。优选地，车窗是汽车车窗。
附图说明
现在将仅通过例子并且参考附图描述本发明，其中：
图1是具有安装于其上的电连接器的车窗的透视图(不按照比例)。
图2是在图1中使用的电连接器的透视图(不按照比例)；和
图3是图1的连接器的一部分的示意性横截面。
具体实施方式
在汽车车窗工业中使用各种电连接器以使车窗面上或其中所提供的电路连接到车辆的线束。常用的连接器被称作丁字片，并且通常是“T”形的，尽管已知例如J-形连接器和条形的其它连接器。每种类型的连接器具有三个共同的特征：由凸起的桥接部分连接的两个连接器脚；在每个连接器脚的底部的突起；并且每个由如铜的金属材料的薄条或片构成。然而，使用在连接器的脚处不具有突起的连接器也是普遍的。尽管以下的例子是以丁字片的方式描述的，本发明的主旨可以应用于所有具有这些特征的电连接器的类型。
图1是具有焊接到导电层13的电连接器14的汽车车窗10的透视图(不按照比例)。汽车车窗10包括一片车窗材料11，如在一个表面上具有烧结黑陶瓷装饰边12的一层钢化玻璃。在装饰边12上提供被称为汇流条的导电层13，通常通过利用导电含银油墨印刷装饰边12的表面。在构成前风窗、后窗和某些顶窗的车窗上提供装饰边12，但可能没有在构成边窗的车窗上提供。在这种情况下，直接在车窗材料11的表面上提供汇流条13。
在汇流条13上安装电连接器14。电连接器14包括一对用于连接到汇流条13的连接器脚15，和用于连接到其中装备车窗的车辆的线束的连接器臂16。连接器脚15被连接到一起并且通过称为桥接17的凸起的部分连接到连接器臂16。每个连接器脚15通过在每个脚15和汇流条13之间的一层焊料18被连接到车窗。
图2是更详细地示出电连接器14的透视图(不按照比例)。电连接器14由如铜的金属材料的薄条或片构成。桥接17相对于连接器脚15和连接器臂16处于固定位置，以使得当电连接器14在适当的位置被焊接时，桥接17处于在连接器脚15的底部之上的高度h。
图3是安装在车窗10上的单个连接器脚15的示意性横截面。在连接器脚15的底部提供一对突起或凹陷19，每对具有高度d。突起19确保了脚15的主体保持在汇流条13之上的固定高度。在使用中，焊料层18将完全围绕突起19并且接触连接器脚15的底部，但是为了清楚起见这从图13被忽略。
电连接器14可以利用各种技术被焊接到汇流条，包括热空气、热烙铁和电阻加热。通常的焊接时间在1秒到3秒之间，需要2到4秒的冷却时间。在连接器脚15到汇流条13的焊接过程中，脚之间的车窗材料11的区域与其被加热到大约焊接温度的连接器桥接17相比保持相对较冷。这导致连接器桥17和车窗材料11之间的膨胀的差异。当焊料层18固定时，连接器桥接17的冷却温度变化比车窗材料11的大很多，导致连接器桥接17和车窗材料11之间的收缩的差异。这种膨胀和收缩的不匹配导致在已经应用焊料18的区域中的车窗材料的表面中应力的产生。在直接在连接器脚15之下的车窗材料11的区域中，拉伸应力产生，而在连接器桥接17下的车窗材料11的区域中，收缩应力产生。任何在车窗材料表面中的缺陷都产生高拉伸应力的区域。
在本发明中应该理解，连接器的优化设计提供了现有技术的方法的实用替代，以提高电连接器和在汽车车窗上的汇流条之间的焊料接合的可靠性。特别地，连接器的设计的以下两个特征可以被优化以提高连接器和汇流条之间的附着力：
a)连接器桥接的高度h；和
b)在连接器脚上的突起的高度d。
在以下每个测试中，所使用的金属连接器都是丁字片类型的。
连接器桥接高度
执行测试以确定刚刚焊接之后连接器桥接高度对附着力的影响。样品由4mm厚的平面浮法玻璃制成，具有烧结油墨装饰边(使用IT57M202黑色陶瓷墨印刷，可从Johnson Mathey，Fregatweg 38，6222NZ Masstricht，The Netherland获得)，并且汇流条使用SP1876含银油墨印刷(可从Ferro AG，Gutleutstrasses 215，PO Box 110403，D-60039，Frankfurt-am-Main，Germany获得)。所使用的焊料是含铅焊料，包括重量百分比为25％的锡、62％的铅、3％的银和10％的铋(可从Anglo Production Processes，Saxon Business Park，HanburyRoad，Stoke Prior，Bromsgrove，Worcestershire B60 4AD获得)。在印刷和焊接之间玻璃被钢化。使用一种其中连接器被垂直于玻璃的表面拉伸的垂直拉伸测试以测量把连接器从汇流条拉伸的所需负荷。使用桥接高度为0.5mm、1.0mm、1.5mm和2.0mm的连接器。移除连接器所需的平均负荷在表1中示出。
 
桥接高度0.5mm 桥接高度1.0mm 桥接高度1.5mm 桥接高度2.0mm
负荷(kg) 负荷(kg) 负荷(kg) 负荷(kg)
29.0 33.7 35.1 35.4
表1：桥接高度测试样品的平均施加负荷
观察到三种故障机制：连接器通过所焊接的接合点的故障变得分离；故障在所焊接的接合点和玻璃表面发生；和所焊接的接合点故障之前在所焊接的接合点区域中的玻璃粉碎。
如可从表1中看出的，所施加的移除连接器的平均负荷随桥接高度的增高而增加。因此，连接器的附着力随桥接高度的增高而增加。桥接高度的优选范围是1.0mm到5.0mm，上限范围仅由包括连接器馈电和空间限制的因素限制。
连接器脚突起高度
为了确定在连接器的每个脚上的突起高度怎样影响连接器与汇流条的附着力，在焊接之后立即以及在加速老化之后，其中四组分别具有不同突起高度的样品被拉伸测试。每个连接器脚具有两个突起，高度为0mm(即无突起)、0.3mm、0.5mm和0.75mm。连接器被焊接到使用在5.0mm厚的平面清洁浮法玻璃上(样品尺寸300mm×300mm)的80％的银和50％的银的混合物(给出的整体银含量是77％)糊料(可作为1749和1752从Chimet Thick Film Division，Via di Pescaiola 74，52040 Viciomaggio(Arezzo)，Italy获得)印刷的汇流条上。车窗在印刷完之后焊接之前被钢化。
表2示出了刚刚焊接之后对于每个突起高度把连接器从汇流条拉伸所需的负荷。使用三种不同的焊料：含铅焊料(包括重量百分比为62％的铅、25％的锡、3％的银和10％的铋(可从Litton，6 FirstAvenue，Globe Park，Marlow，SL 7 1YA获得))；无铅焊料(1)(包括重量百分比为42％的锡、57％的铋和1％的银(可从Indium(UK)，7Newmarket Court，Kingston，Milton Keynes，MK10 0AG获得))和无铅焊料(2)(包括重量百分比为95.5％的锡、3.8％的银和0.7％的铜(可从Multicore Solders Ltd，Kelsey House，Wood Lane End，Hemel Hempstead，HP2 4RQ)获得)。
表2：焊接之后移除连接器的所需平均负荷
表3示出了加速老化之后对于每个突起高度把连接器从汇流条拉伸所需的负荷。样品在50℃和95％的相对湿度的风化柜中被老化14天。再一次，使用三种不同的焊料：含铅焊料(包括重量百分比为62％的铅、25％的锡、3％的银和10％的铋)；无铅焊料(1)(包括重量百分比为42％的锡、57％的铋和1％的银)和无铅焊料(2)(包括重量百分比为95.5％的锡、3.8％的银和0.7％的铜)，如前所述所有都可获得。
Figure A200780017259D00111
表3：在50℃和95％的相对湿度中14天之后移动连接器所需的平均负荷
对于含铅焊料，表2和3中的结果表明刚刚焊接之后和加速老化之后突起高度的增加对于连接器和汇流条之间的附着力的影响很小。然而，对于两种无铅焊料合成物，增加突起高度导致刚刚焊接之后附着力的增加。老化之后，对于两种无铅焊料合成物看出最优的突起高度是0.50mm。从表2和3中的趋势可以看出，在优选为0.3mm到0.75mm范围内的高度之下，所希望的突起的上限是1.0mm。
为了优化电连接器的设计，这些因素中的至少一个可以用于增加连接器和汇流条之间的附着力。
优选地，可以这两者结合起来。为了提供足够的附着力，d和h最好在1.0mm≤h≤5.0mm和0.00mm≤d≤1.00mm的范围之内，并且把连接器从汇流条移除所需的平均负荷大于或者等于20kg。通过改变和优化每个桥接高度和突起高度，可以得到一种丁字片设计，其提高了连接器和其所施加的汇流条之间的附着力。当使用无铅焊料时，优化优的设计特别地有效。

Claims (15)

1.一种车窗，包括一层车窗材料，所述车窗材料具有安装于其上的第一导电部件，以及通过焊料被接合到所述第一导电部件的第二导电部件，所述第二导电部件包括由桥接部分链接的第一和第二连接器脚，所述桥接部分处于在每个所述连接器脚之上的高度h处，并且每个所述脚包括至少一个具有高度d的突起，其中选择t或h中的至少一个以最大化所述第二导电部件和所述第一导电部件之间的附着力。
2.如权利要求1中所述的车窗，其中h在1.0mm到小于等于5.0mm的范围内。
3.如权利要求1或2中所述的车窗，其中d在0.00mm到1.0mm的范围内。
4.如权利要求1或2所述的车窗，其中d在0.3mm到0.75mm的范围之内。
5.如上述权利要求中任一项所述的车窗，其中当所述第一导电部件被置于平面浮法玻璃上，并且所述第二导电部件焊接到其上时，选择h或d中的至少一个使得移除所述第二导电部件所需的平均负荷大于20kg。
6.如上述权利要求中任一项所述的车窗，其中选择h和d以提高在所述第二导电部件和所述第一导电部件之间的附着力。
7.如上述权利要求中任一项所述的车窗，其中选择h和d以提高在50℃和95％的相对湿度中14天之后在所述第二导电部件和所述第一导电部件之间的所述附着力。
8.如上述权利要求中任一项所述的车窗，其中所述第二导电部件由铜制成。
9.如上述权利要求中任一项所述的车窗，其中所述第一导电部件是汇流条。
10.如上述权利要求中任一项所述的车窗，其中所述一层车窗材料的表面使用烧结油墨边围绕它的周边印刷。
11.如权利要求11中所述的车窗，其中所述第一导部件的至少一部分在所述烧结油墨边上提供。
12.如上述权利要求中任一项所述的车窗，其中所述第二导电部件是丁字片连接器。
13.如上述权利要求中任一项所述的车窗，其中所述焊料是无铅焊料。
14.如上述权利要求中任一项所述的车窗，其中所述车窗是汽车车窗。
15.一种车窗，具有焊接到其上的电连接器，基本上如在此描述的，并且参考附图。
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