High wattage solderless flexible connector for printed conductors

Patent metadata

Field	Value
Publication number	US-10601148-B2
Application number	US-201816167832-A
Country	US
Kind code	B2
Filing date	Oct 23, 2018
Priority date	Oct 23, 2017
Publication date	Mar 24, 2020
Grant date	Mar 24, 2020

Abstract

An adhesive connector for making an electrical connection to a conductor formed on a support surface is provided. The adhesive connector includes a substrate and a metal strip attached to a first surface of the substrate, wherein the metal strip is configured to engage a releasable electrical connector. The adhesive connector also includes a conductive strip attached to a second surface of the substrate and a conductive staple configured to secure the conductive strip, the substrate, and the metal strip together. The adhesive connector further includes an electrically-conducting adhesive that coats a first portion of the conductive strip, and is configured to provide electrical contact to a conductor formed on a support surface.

First claim

We claim:

1. An adhesive connector for making an electrical connection to a conductor formed on a support surface, the adhesive connector comprising:
a substrate;
a metal strip attached to a first surface of the substrate, wherein the metal strip is configured to engage a releasable electrical connector;
a conductive strip attached to a second surface of the substrate;
a conductive staple configured to secure the conductive strip, the substrate, and the metal strip together; and
an electrically-conducting adhesive that coats a first portion of the conductive strip, and is configured to provide electrical contact to a conductor formed on a support surface,
wherein the conductive staple comprises a flat head and prongs, wherein the flat head abuts and electrically communicates with a surface of the conductive strip, and the prongs extend through the conductive strip, the substrate, and into holes of the metal strip.

2. The adhesive connector of claim 1 , wherein the substrate is constructed using a flexible polymer.

3. The adhesive connector of claim 1 , wherein the metal strip further comprises:
a first portion that is configured to attach to, and lie coplanar with, the first surface of the substrate, and
a second portion that is canted away from first surface of the substrate, and configured to engage the releasable electrical connector.

4. The adhesive connector of claim 1 , wherein the conductive strip is constructed using laminated foil or printed conductive ink.

5. The adhesive connector of claim 1 , wherein a width of the conductive strip is substantially the same or greater than the width of the conductor.

6. The adhesive connector of claim 5 , wherein the width of the conductive strip is greater than the width of the conductor by approximately between 10% to 20%.

7. The adhesive connector of claim 1 , wherein the conductive strip is positioned along a midline of the substrate that extends along a long dimension of the substrate.

8. The adhesive connector of claim 1 further comprising a heat sink positioned between the first surface of the substrate and the metal strip.

9. The adhesive connector of claim 1 further comprising an electrically-insulating adhesive that coats a second portion of the conductive strip.

10. The adhesive connector of claim 9 , wherein the electrically-conductive adhesive extends over a first area of the second surface of the substrate, and the electrically-insulating adhesive extends over a second area of the second surface of the substrate.

11. The adhesive connector of claim 1 , wherein an area of the substrate is sufficient to relieve a strain on the conductor formed on the support surface.

12. The adhesive connector of claim 1 further comprising a second conductive strip attached to the second surface of the substrate, and a second metal strip attached to the first surface of the substrate, to electrically connect a second conductor formed on a support surface to a second releasable electrical connector.

13. The adhesive connector of claim 12 , wherein the electrically-conducting adhesive coats a portion of the second conductive strip.

14. The adhesive connector of claim 13 , wherein the electrically-conducting adhesive is an anisotropic electrically-conducting adhesive configured to conduct electricity in a direction that is perpendicular to a plane defined by the second surface of the substrate.

15. The adhesive connector of claim 1 further comprising a release liner covering the electrically-conducting adhesive.

16. An adhesive connector for making an electrical connection to a printed conductor formed on a glass surface, the adhesive connector comprising:
a flexible substrate configured to conform to a glass surface;
a metal strip attached to a first surface of the flexible substrate, wherein the metal strip is configured to engage a releasable electrical connector;
a conductive strip attached to a second surface of the flexible substrate;
a conductive staple configured to secure the conductive strip, the flexible substrate, and the metal strip together; and
an electrically-conducting adhesive that coats a first portion of the conductive strip, and is configured to provide electrical contact to a printed conductor formed on the glass surface,
wherein the conductive staple comprises a flat head and prongs, wherein the flat head abuts and electrically communicates with a surface of the conductive strip, and the prongs extend through the conductive strip, the substrate, and into holes of the metal strip.

17. The adhesive connector of claim 16 , wherein the printed conductor forms a heater.

18. The adhesive connector of claim 16 further comprising a heat sink positioned between the first surface of the flexible substrate and the metal strip.

19. The adhesive connector of claim 16 further comprising an electrically-insulating adhesive that coats a second portion of the conductive strip.

Assignees

• Illinois Tool Works

Inventors

• Bulgajewski Edward F
• Sliwa Piotr
• Healey John F

Classifications

• H05B2203/031

  Heaters specially adapted for heating the windscreen wiper area · CPC title

• H01R4/06

  Riveted connections (by explosion H01R4/08) · CPC title

• H05B2203/016

  Heaters using particular connecting means · CPC title

• H05B3/84

  Heating arrangements specially adapted for transparent or reflecting areas, e.g. for demisting or de-icing windows, mirrors or vehicle windshields · CPC title

• H05K3/323

  by applying an anisotropic conductive adhesive layer over an array of pads · CPC title