Printed circuit glass

Abstract

To provide a method and system for providing electrical connectivity to components integrated within an automotive windshield.SOLUTION: The system includes a laminated glass structure with low resistance, highly conductive traces printed directly onto one of the glass surfaces. These conductive traces are designed to carry electrical current to various devices that are either embedded in or attached to the windshield, such as sensors and cameras used in advanced driver assistance systems (ADAS). The conductive traces are created in some examples using a conductive paste applied through a screen printing process and cured to form solid conductive lines. This approach eliminates the need for traditional wiring harnesses, simplifies the vehicle assembly process, reduces manufacturing complexity, and allows for more flexible placement of devices on the windshield.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present disclosure relates generally to printed circuit glass, and in some instances to automotive windshield technology, and specifically to printing low resistance traces for powering or connecting devices on laminated glass structures within vehicles. Examples include integrated electrical systems for powering devices, and advances in methods for applying and curing low resistance conductive traces on glass surfaces to facilitate direct connection of electrical components without the need for traditional wiring harnesses. [Background technology]

[0002] Automotive windshields have evolved from simple barriers against environmental elements to complex components that fulfill multiple roles in the functionality and safety of a vehicle. Modern vehicles incorporate various technologies into the windshield, such as heating elements to prevent ice formation and sensors for advanced driver assistance systems (ADAS). These technologies typically require power, which is supplied through a traditional wiring harness. A wiring harness is a network of electrical cables that provide power and data connections to various parts of the vehicle, including the windshield.

[0003] Some traditional high resistance elements are used to defrost the windshield in front of the camera for ADAS functions in the "wiper park" position to melt or defrost ice around the wiper blades in the "park" or non-operating position and prevent the wipers from freezing to the glass. Such traditional designs also typically include harnesses that connect these heating elements to the vehicle's power source and other devices on the windshield.

[0004] The assembly and integration of these harnesses into the vehicle structure is a complex process involving multiple components and steps. As automotive technology advances, the desire to integrate more functionality into the windshield increases, increasing the complexity of the vehicle's electrical system. This complexity can impact manufacturing, maintenance, and vehicle design. Summary of the Invention

[0005] As previously mentioned, an automotive windshield functions as the vehicle's front window, providing visibility for the driver while protecting the vehicle's occupants from the elements. Over time, the functionality of the windshield has expanded beyond these basic roles. Today's windshields often incorporate additional features, such as defrosting systems and sensors, that contribute to the safety and comfort of the vehicle.

[0006] One common feature is windshield heaters, which are designed to remove frost, ice, or condensation from the windshield. This is typically accomplished by using a heating element built into the windshield. These elements are often made from high-resistance wire, which has high resistance properties that allow it to generate heat when an electric current passes through it. The heat generated by the material's resistance is sufficient to melt the ice or remove the condensation, ensuring good visibility through the windshield.

[0007] Another increasingly common feature in modern vehicles is the incorporation of sensors and cameras, especially for vehicles equipped with advanced driver assistance systems (ADAS). These systems rely on clear visibility through the windshield for functions such as adaptive cruise control, lane-keeping assistance, and emergency braking. To maintain this visibility, especially in cold climates, it may be necessary to prevent ice and fog from obscuring the sensors and cameras. This is often accomplished by extending heating elements into the area of ​​the windshield in front of these devices.

[0008] Traditionally, the power required for these windshield mechanisms is supplied through a wiring harness, which is a bundle of wires that provides electrical connections throughout the vehicle. In the context of the windshield, the harness connects the heating elements and sensors to the vehicle's power and control systems. The harness often requires careful routing and connection during vehicle assembly, which can be a complex and labor-intensive process.

[0009] The present disclosure relates to a method and system for providing electrical connections to components installed within an automotive windshield. The system includes a laminated glass structure with conductive traces printed directly onto one of the glass surfaces. These conductive traces are designed to carry electrical current to various devices embedded in or attached to the windshield. [Brief explanation of the drawings]

[0010] Throughout the drawings, reference numbers may be reused to indicate correspondence between referenced elements. The drawings are provided to illustrate examples of the subject matter described herein and not to limit the scope thereof.

[0011] [Figure 1] 1 illustrates an aspect of the subject matter according to one embodiment.

[0012] [Figure 2] 1 illustrates an aspect of the subject matter according to one embodiment.

[0013] [Figure 3] 1 illustrates an aspect of the subject matter according to one embodiment.

[0014] [Figure 4] 1 illustrates an aspect of the subject matter according to one embodiment.

[0015] [Figure 5] FIG. 1 is a flow diagram illustrating example operations in a method according to one embodiment.

[0016] [Figure 6] FIG. 1 is a system block diagram illustrating an electric vehicle (EV) architecture, according to some examples. DETAILED DESCRIPTION OF THE INVENTION

[0017] The examples described herein aim to provide a different approach to providing electrical connections to a windshield. Instead of using a traditional wiring harness, some examples involve printing low-resistance conductive traces directly onto the windshield. These traces act as a path for electrical current. In some examples, the conductive traces are created using a conductive paste that is applied to the windshield using a screen printing process. Once applied, the paste is cured to form solid conductive lines capable of carrying electrical current.

[0018] The conductive paste used in these traces has a much lower resistance than the paste used in heating elements. In some instances, this low resistance allows for efficient conduction of electricity to power devices without generating undesirable heat. In some instances, the resistance specification for these conductive traces is approximately 0.1 ohms per meter, which is significantly lower than the resistance of traditional heating elements, which can range from 5 to 10 ohms per meter.

[0019] Some of the described examples also include disclosure of how devices can be connected to these conductive traces. One exemplary method involves the use of spring contacts or other types of connectors that can make a secure electrical connection with the traces. These connectors can be mounted on the windshield and provide a point at which devices such as sensors or controllers can be connected to the electrical system without the need for a traditional wiring harness.

[0020] By printing low-resistance conductive traces directly onto the windshield, the described examples aim to simplify the vehicle assembly process. In some instances, this approach can reduce the number of components required for electrical connections, potentially streamlining the manufacturing process. Additionally, it can provide more flexibility in the placement and integration of devices on the windshield.

[0021] Some described examples also contemplate powering a wide range of devices via the conductive traces. The ability to deliver power directly to the windshield allows for the integration of additional features and components not possible with traditional wiring harnesses. These components may include sensors, lighting, cameras, or other electronic components that enhance the functionality of the windshield and vehicle. By using printed, low-resistance conductive traces, some examples address the complexities associated with traditional wiring harnesses and open up new possibilities for incorporating technology into the windshield.

[0022] FIG. 1 shows a pictorial diagram of a cross section of a traditional windshield 102. One common feature is a windshield heater designed to remove frost, ice, or condensation from the glass. This is typically accomplished through the use of one or more high-resistance heating elements 104 incorporated into the windshield. These elements are often made from high-resistance wire, which has high resistance properties that allow it to generate heat when an electric current passes through it. The heat generated by the resistance of the material is sufficient to melt the ice or remove the condensation, ensuring good visibility through the windshield.

[0023] Another feature that is becoming increasingly common in modern vehicles is the incorporation of sensors and cameras for vehicles equipped with advanced driver assistance systems (ADAS), typically located in the upper center region of the traditional windshield 102, as shown, for example, in ADAS component 106. These systems rely on clear visibility through the windshield for functions such as adaptive cruise control, lane-keeping assistance, and emergency braking. To maintain this visibility, especially in cold weather, it may be necessary to prevent ice and fog from obscuring the sensors and cameras. This is often accomplished by extending a high-resistance heating element 104 into the area of ​​the windshield in front of these devices. A traditional high-resistance heating element 104 may also be used to defrost the traditional windshield 102 in the "wiper park" position to prevent the windshield wipers from freezing to the glass.

[0024] Traditionally, the power required for these ADAS components 106 is provided via a wiring harness, such as wiring harness 108. A wiring harness is a bundle of wires that provides electrical connections throughout a vehicle. In the context of the windshield, the harness connects the heating elements and sensors to the vehicle's power source, such as power supply 110, and other control systems. The harness must be carefully routed and connected during vehicle assembly, which can be a complex and labor-intensive process. This traditional approach can also suffer from certain drawbacks discussed above.

[0025] FIG. 2 shows a pictorial view of a vehicle windshield 202. Some examples herein provide methods for providing electrical connectivity to the windshield 202. In one embodiment, the windshield 202 includes a glass substrate 218 and one or more low-resistance traces 204 screen-printed onto the glass substrate 218 using a conductive paste. Exemplary conductive pastes and methods for screen-printing the same are described further below. A cross-sectional view of an exemplary glass substrate 218 is shown in FIG. 4, which is described further below. In some examples, the low-resistance traces 204 are screen-printed above or below a layer of black ceramic frit 212.

[0026] In some examples, the linear resistance of the low resistance trace 204 is much lower than conventional heating wire or trace. In some examples, the low resistance trace 204 has a linear resistance in the range of 0.05 to 5 ohms / meter. In some examples, the low resistance trace 204 has a linear resistance in the range of 0.1 to 3 ohms / meter. In some examples, the low resistance trace 204 has a linear resistance in the range of 0.1 to 1 ohm / meter. In some examples, the low resistance trace 204 has a linear resistance of 0.1 ohm / meter.

[0027] In some instances, these low values ​​of linear resistance result in low-resistance traces 204 that have much higher electrical conductivity than conventional heating wires or traces. In some instances, this low resistance (or high electrical conductivity) can efficiently conduct electricity to power devices without generating undesirable heat. In some instances, the resistance specification for these highly conductive traces is significantly lower than the resistance of traditional heating elements, which can be in the range of 5-10 ohms per meter.

[0028] In some examples, the width 222 of the low resistance trace 204 is provided on the windshield 202 in the range of 3 to 10 millimeters (mm). In some examples, the width of the low resistance trace 204 is held constant along its length at a width of about 4 mm. Other widths of the low resistance trace 204 are also contemplated, for example, to adjust the linear resistance or conductivity of the low resistance trace 204.

[0029] In some examples, the low resistance traces 204 are insulated from other low resistance traces 204 on the windshield 202 by a trace separation distance 224, such as shown between a pair of low resistance traces 204 in Figure 2. In some examples, the trace separation distance 224 is provided in the range of 2-10 mm, and in some examples, a trace separation distance 224 of at least 5 mm is provided. Other trace separation distances are possible, for example, to adjust the degree of isolation between low resistance traces 204 running in parallel directions across the windshield 202.

[0030] In some examples, a connector 216 is electrically connected to one or more low-resistance traces 204 on the windshield 202. In some examples, the connector 216 is integrated onto a glass substrate 218 to electrically connect the low-resistance traces 204 to the vehicle's electrical panel 210, the components 214, or the power source 220. In some examples, these electrical connections can be made conveniently without the need for a traditional wiring harness, such as the wiring harness 108 of FIG. 1 . Electrical access to the components 214 can be facilitated by providing the vehicle's electrical panel 210 with one or more low-resistance traces 204. In some examples, the vehicle's electrical panel 210 is located within or adjacent to a camera zone 230 of the windshield 202. The vehicle's electrical panel 210 has an exterior surface 232 (i.e., facing the exterior of the vehicle) and an interior surface 234 (i.e., facing the interior of the vehicle). In some examples, the connector 216 may be electrically connected to a power source 220 to provide power to the electrical panel 210 and / or components 214 of the vehicle.

[0031] In some examples, the windshield 202 further includes one or more first high-resistivity traces 206 and one or more second high-resistivity traces 208. In some examples, the first high-resistivity traces 206 and / or the second high-resistivity traces 208 are also screen-printed onto the windshield 202; in these examples, an electrically highly resistant paste is used in the screen-printing process. In some examples, the one or more first high-resistivity traces 206 may power or function as an ice-release heater for the windshield wipers in the "park" position. The park position may be along the lower edge of the glass substrate 218 of the windshield 202. In some examples, the one or more second high-resistivity traces 208 may power or function as a defrost heater for a camera in a camera zone 230 of the windshield 202. Power connection to the first high resistance trace 206 and / or the second high resistance trace 208 may, in some examples, be made via one or more heater contacts 228 provided on an interior surface 234 of the vehicle's electrical panel 210. These are labeled CH (camera heater) and HWP (wiper park heater), by way of example only. In some examples, a ground contact 236 (labeled GRD) is also provided. Electrical connection to these heater contacts 228 may, in some examples, be facilitated by the provision of one or more contactors 226. The contactors 226 may, for example, be spring-loaded or otherwise configured to facilitate safe and easy connection to other components or external devices, as desired.

[0032] 3, in some examples, the conductive paste 304 used to form the low resistance traces 204 by screen printing is comprised of or includes a silver paste 306. In some examples, the silver paste 306 includes an inorganic ceramic frit 308, a silver-based compound 310, and a liquid medium 312. Additional or other components of the conductive paste 304 are possible, for example, as described below.

[0033] A mesh screen 302 is prepared with a desired pattern 314 for one or more low-resistance traces 204 to be formed on the glass substrate 218 of the windshield 202. The mesh screen 302 allows the conductive paste 304 to pass through in specific areas corresponding to the pattern 314. By way of example only, a simple rectangular pattern 314 is shown in the figure. Other more complex, thin-line, and / or sophisticated patterns 314 for the one or more low-resistance traces 204 on the glass substrate 218 are possible.

[0034] In an example application of conductive paste 304, conductive paste 304 is deposited on glass substrate 218. A scraper 316 is then used to press conductive paste 304 through mesh screen 302 onto glass substrate 218 (i.e., in some examples, the inner surface of windshield 202). The pressure and angle of scraper 316 are controlled to ensure a consistent application.

[0035] In an exemplary transfer of the pattern 314, as the scraper 316 moves across the glass substrate 218, the conductive paste 304 is transferred onto the glass substrate 218 within the pattern 314 defined by the mesh screen 302. In some examples, the thickness of the paste layer can be adjusted by the mesh count of the mesh screen 302 and the viscosity of the conductive paste 304.

[0036] In an example of removing the mesh screen 302, after the conductive paste 304 is applied, the mesh screen 302 is lifted off, thereby leaving the patterned conductive paste 304 on the glass substrate 218, i.e., the windshield surface.

[0037] Once the conductive paste 304 is applied, in some instances, the conductive paste must be cured to form a solid conductive trace (i.e., a low-resistance trace 204). The curing method may vary depending on the type of conductive paste 304 used, but in some instances includes thermal curing, in which the glass substrate 218 or windshield 202 with the applied conductive paste 304 is placed in an oven or passed through a heating tunnel, which applies controlled heat to cure the conductive paste 304. For conductive pastes 304 that are sensitive to ultraviolet (UV) light, a UV curing process may be used. The applied conductive paste 304 is exposed to UV radiation, which initiates a chemical reaction that solidifies the paste. Some conductive pastes 304 may cure over time at room temperature. This method is less common in automotive applications due to the long curing time required.

[0038] In some applications, the conductive paste 304 is a critical component of the system and / or method for providing electrical connectivity to a vehicle windshield, as its properties determine the electrical performance of the traces. The conductive paste 304 options may include silver-based pastes. Silver provides high conductivity and is a convenient choice for conductive applications. Silver pastes can be formulated using a mixture of silver particles and a binder to create a printable material.

[0039] Another or further example may include copper-based pastes. Copper is another highly conductive material that can be used in paste form. Copper pastes may require oxidation protection to maintain conductivity. Another or further example may include carbon-based pastes. Carbon or graphite pastes provide lower conductivity than metals but may be a cost-effective alternative for certain applications. Another or further example may include conductive polymers. While inherently conductive polymers can be used to form low resistance traces 204, they generally provide lower conductivity compared to metals.

[0040] Each conductive paste 304 option may have a unique set of properties, including resistance, adhesion, flexibility, and environmental stability. The selection of conductive paste 304 may depend on the specific requirements of the application, such as the amount of current the traces need to carry and the environmental conditions to which the traces will be exposed. In some examples, the manufacturing process for applying conductive traces to a windshield involves a coordinated sequence of screen printing and curing, utilizing conductive pastes selected for their electrical properties and compatibility with automotive standards.

[0041] In some examples, a method for providing electrical connectivity to a vehicle windshield includes applying a conductive paste to a surface of the windshield in a predetermined pattern via a screen printing process, curing the conductive paste to form low resistance conductive traces, and connecting electrical components to the low resistance conductive traces.

[0042] In some examples, the conductive paste comprises a silver-based material, in some examples, the conductive paste comprises a copper-based material, in some examples, the conductive paste comprises a carbon-based material, in some examples, the conductive paste comprises an inherently conductive polymer.

[0043] In some examples, curing the conductive paste comprises a thermal curing process. In some examples, curing the conductive paste comprises a UV curing process.

[0044] In some examples, the low resistance conductive trace has an electrical resistance of about 0.1 ohms per meter.

[0045] In some examples, a vehicle windshield includes low-resistance conductive traces formed on a surface of a laminated glass structure from a cured conductive paste, and a connector that interfaces with the low-resistance conductive traces to provide power to devices attached to the windshield. In some examples, the low-resistance conductive traces are formed using a screen printing process. In some examples, the conductive paste is selected from a group including silver-based materials, copper-based materials, carbon-based materials, and / or conductive polymers. In some examples, the connector includes spring contacts.

[0046] In some examples, a system for powering devices on a vehicle windshield includes one or more low-resistance conductive trace screens printed on the windshield, a connector assembly attached to the windshield and electrically connected to the one or more conductive traces, and one or more devices powered by the conductive traces. In some examples, the one or more devices include sensors for advanced driver assistance systems. In some examples, the one or more devices include heating elements for defrosting the windshield. In some examples, the low-resistance conductive traces are configured to distribute power to multiple devices simultaneously.

[0047] In some examples, the low resistance conductive traces are printed on the interior surface of the windshield facing the passenger compartment. In some examples, the connector assembly is attached to the windshield using an adhesive. In some examples, the low resistance conductive traces are printed in a pattern corresponding to the layout of devices on the windshield. In some examples, the low resistance conductive traces are printed in various widths to accommodate different current carrying requirements of devices.

[0048] In other embodiments, the conductive paste 304 used to form low-resistance conductive traces on the windshield exhibits a linear resistance not exceeding 0.1 ohms / meter. This engineering requirement may be met in some instances by the choice of conductive metal or by optimizing the geometry of the printed trace, such as increasing the trace width to reduce resistance. If the conductive paste 304 does not meet the feasibility criteria, alternative materials may be considered. Some examples demonstrate the ability to fuse with ceramic enamel in a manner comparable to silver, thereby ensuring compatibility with screen printing processes on glass substrates.

[0049] In some examples, the screen printing process begins with the deposition of an inorganic ceramic paste onto the glass surface. The ceramic paste may be included in or provide the conductive paste 304, as described above. In some examples, the ceramic paste is a blend of glass "frit" (small granular glass fragments), coloring pigments, and a vehicle that acts as a solvent. The mixture of glass frit, pigment, and vehicle softens and fuses upon application and subsequent heating to produce a ceramic paste that forms a durable glass layer that is chemically and mechanically bonded to the substrate. This paste may be prepared in a premixed form or as a powder that is later combined with the vehicle.

[0050] In some instances, the screen printing process is performed on the "air side" of the glass to ensure a defect-free application. The printing environment is dust-free to prevent surface defects. Following printing, a drying or pre-baking step may be performed to remove moisture.

[0051] After printing, the applied ceramic paste (e.g., conductive paste 304) is typically subjected to firing in a bending furnace at temperatures exceeding 600°C. This step ensures complete combustion of the media, leaving only the frit and pigment. The resulting frit becomes an integral part of the glass surface and exhibits excellent durability and suitability for a variety of applications, including resistance to fading, UV exposure, temperature changes, and chemicals.

[0052] In some examples, the minimum width of the screen-printed low-resistance traces 204 is 0.4 mm. The layout of these low-resistance traces 204 may be determined based on the location of the device to be powered and the connection points on the vehicle body. To ensure electrical isolation, some low-resistance traces 204 may be printed with a minimum spacing of 5 mm and may be located above or below a layer of black ceramic frit.

[0053] In some examples, there may not be a predetermined maximum for the current and voltage that the printed low-resistance trace 204 can handle, but rather the design is tailored to the supply voltage and power and heating requirements of a given component. For applications other than heating, such as the examples disclosed herein, in some examples, testing is performed to confirm maximum current and voltage capabilities to ensure that, for example, the silver low-resistance trace 204 can accommodate automotive devices up to 48V. In some examples, the electrical performance of the low-resistance trace 204 is not as significantly affected by environmental factors such as temperature and humidity as wire conductors because the low-resistance trace 204 is typically shielded from the "wet side" of the vehicle.

[0054] A series of tests, including functional integrity tests involving cycling of exposure to extreme temperature and humidity levels, were performed in some instances to ensure the durability of the highly conductive, low resistance traces 204. These tests confirm that the glazing assembly maintains full integrity between -40°C and +108°C over a humidity range of 0% to 100% and that no delamination of the silver print is permitted.

[0055] 4, in some instances, a safety glass component, windshield 202, complies with regulations such as FMVSS 205 that require it to be impervious to penetration while maintaining a certain level of strength. As a result, windshield 202 may be constructed as a laminated glass stack, as shown, including at least two pieces of glass joined together with an interlayer that maintains this required strength level. An exemplary low-resistance trace 204 is shown formed by screen printing on the air-side surface S4 of windshield 202.

[0056] Some examples herein facilitate integration with the vehicle electrical system. To this end, the printed conductive low-resistance traces 204 may include the use of contactors (such as contactor 226 in FIG. 2 ). Further considerations for the vehicle's electronic control unit (ECU) may include maintaining connectivity with the main controller through the vehicle harness. These harnesses connect to the windshield through a primary connector, thereby requiring a contactor on the other side to direct current to the printed traces. Upon assembly of the windshield to the vehicle, the contactor establishes contact, thereby enabling electrical connection. Accordingly, further examples may include new contactor designs or replacements and optimization of the coaxial cable.

[0057] In some examples, the technology disclosed herein extends beyond windshields to other applications, such as printing conductive traces on glass for additional locations. For example, a center high-mounted stop light (CHMSL) can be added to a rear windshield glass (also known as a backlight) by taping it in, provided it has a contactor. Additionally, conductive paste 304 can be printed onto plastic using digital printing for a radar heater on the fascia, or to power devices such as an ultrasonic sensor on the fascia, without the need for a wire harness.

[0058] Some examples herein include methods. Referring to FIG. 5 , in some examples, a method 500 for providing an electrical connection to a vehicle windshield is provided. While flow diagrams described herein may depict operations as sequential processes, many of the operations may be performed in parallel or simultaneously. Furthermore, the order of operations may be rearranged. A process terminates upon completion of the operations. A process may correspond to a method, a procedure, an algorithm, or the like. The operations of a method may be performed in whole or in part, in conjunction with some or all of the operations of other methods, or by any number of different systems, such as the systems described herein, or any portion thereof, such as a processor included in any of the systems.

[0059] In step 502, method 500 includes preparing a conductive paste for forming a low-resistance trace on a windshield, the low-resistance trace having a linear resistance in the range of 0.05 to 3 ohms / meter, the conductive paste including an inorganic ceramic frit, a silver-based compound, and a liquid medium. In step 504, method 500 includes applying the conductive paste to a glass substrate of the windshield using a screen printing process. In step 506, method 500 includes drying the applied conductive paste to remove moisture. In step 508, method 500 includes firing the glass substrate with the applied conductive paste at a temperature greater than 500°C to harden the conductive paste and form a low-resistance trace on the windshield.

[0060] The method may also include where the low resistance trace has a linear resistance in the range of 0.1 to 2 ohms / meter. The method may also include where the low resistance trace has a linear resistance in the range of 0.1 to 1 ohm / meter. The method may also include where the low resistance trace has a linear resistance of 0.1 ohm / meter. The method may also include where the low resistance trace has a width in the range of 3 to 10 millimeters (mm). The method may also include where the low resistance trace has a width of 4 mm. The method may also include where the conductive paste further includes a pigment. The method may also include where the conductive paste is prepared by mixing a premixed frit and a silver-based compound with a liquid medium. The method may also include where the conductive paste is prepared by mixing a powder form of the frit and a silver-based enamel with a liquid medium. The method may also include where the conductive paste is applied to the air side of the glass substrate. The method may also include where the silver-based compound is included in the silver-based enamel. The method may also include testing the formed low resistance trace for a linear resistance value. The method may also further include applying a connector on the glass substrate to connect the low resistance trace to an automotive electrical panel, component, or power source. The method may also include where the low resistance trace is insulated from another low resistance trace by a trace separation distance of at least 5 mm. The method may also include where the low resistance trace is printed above or below a layer of black ceramic frit. Other technical features will be readily apparent to those skilled in the art from the following drawings, description, and claims.

[0061] 6 is an exemplary system block diagram illustrating the architecture of an electric vehicle (EV) 602, according to some examples. The diagram illustrates the systems and subsystems that collectively enable the functionality and operational efficiency of the electric vehicle 10.

[0062] Vehicle 602 includes several interconnected higher-level systems, including a battery system 604, a propulsion system 606, a structural and mechanical system 608, a charging system 610, power electronics 612, a control system 614, a driver interface and infotainment 616, safety systems 618, and auxiliary systems 620.

[0063] The propulsion system 606 includes one or more electric motors 13, which may include traction motors for propulsion and motors for a regenerative braking system, to convert electrical energy into mechanical energy. A power inverter 624 facilitates the conversion of DC power from the battery to the AC power required by the electric motors 626. The propulsion system also includes a transmission 628, which may consist of a single-speed transmission or gearbox, that directs mechanical power to the vehicle's wheels.

[0064] The battery system 604 is composed of several battery modules 630, each housing multiple battery cells 632. These battery cells 632 can be based on a variety of chemistries, including lithium-ion, lithium polymer, or solid-state materials, each offering different characteristics and / or capabilities in terms of energy density, recharge cycles, and safety profile.

[0065] The battery management system (BMS) 634 continuously monitors various parameters, such as voltage, current, and temperature, of each of the battery cells 632 and battery modules 630 to prevent conditions that could lead to overcharge, deep discharge, or thermal runaway. The battery management system (BMS) 634 also manages the battery's state of charge (SoC) and state of health (SoH), ensuring that energy is distributed during discharge and that the charging process is optimized for longevity and safety. Each battery management system (BMS) 634 uses algorithms to balance charge across cells and modules and correct imbalances that could reduce the battery's overall capacity and longevity.

[0066] The battery system 604 incorporates a thermal management system 636 that maintains the battery cells 632 operably within a specified temperature range. The thermal management system 636 uses temperature sensors to monitor the heat generated by the battery cells 632 during operation. Based on the collected data, the thermal management system activates cooling and heating mechanisms to regulate the temperature of the battery. Cooling methods can include air cooling, in which ambient air is circulated around the battery modules, or liquid cooling, in which a coolant is circulated through channels in or around the battery modules to absorb and dissipate heat. In cooler environments, the thermal management system 636 can use heating elements or waste heat from the vehicle's systems to warm the battery cells, allowing them to operate efficiently at lower temperatures.

[0067] The charging system 610 operatively replenishes stored energy within the battery system 604 of the electric vehicle 602. The charging system supports a variety of charging methodologies to ensure flexibility and convenience in energy recovery. The charging system 610 may include both standard (Level 1 and Level 2) and fast charging (DC fast charging) systems, thereby facilitating a range of charging speeds to suit different user needs and infrastructure capabilities.

[0068] For standard charging, the charging system 610 includes an AC / DC on-board charger that converts alternating current (AC) from the power grid or a home outlet into direct current (DC) that can be stored in the vehicle's battery system 604. The on-board charger may support, for example, Level 1 and Level 2 charging, where Level 1 charging uses a standard home outlet (608-120V) and Level 2 charging requires a higher voltage source (208-240V), such as found at dedicated charging stations or installed in a home garage.

[0069] For fast charging, the charging system 610 may incorporate a DC fast charging system designed to bypass the onboard charger and quickly transfer energy directly to the vehicle's battery system 604. A DC fast charging station provides high voltage (e.g., 400V-800V) direct current directly to the battery system 604.

[0070] Additionally, the electric vehicle 602 may be equipped with an auxiliary battery, such as a 12V lead-acid or lithium-ion battery, which may be tasked with powering the vehicle's low-voltage systems, including lighting, infotainment, electronic control units, and other auxiliary components, thereby ensuring operation of the low-voltage systems even when the main battery system is off or during the early stages of charging when the main system voltage may be too low for these tasks. This separation of power sources increases the reliability of the vehicle's electrical system and ensures the availability of potentially critical functions.

[0071] Structural and mechanical systems 608, including chassis and body 638 and suspension system 640, provide the physical framework and support for vehicle 602. Chassis and body 638 constitutes the primary structure of the vehicle, while suspension system 640, which may include springs, shock absorbers (or dampers), and control arms, provides a smooth, stable ride by absorbing road shocks and vibrations.

[0072] Power electronics 612, including a power distribution unit (PDU) 642 and a voltage conversion system 644, is responsible for managing and converting electrical power within the vehicle. The power distribution unit (PDU) 642, equipped with fuses and relays, distributes power to the various vehicle systems, while voltage conversion devices in the voltage conversion system 644, such as DC / DC and AC / DC converters, adjust voltage levels to meet the specific requirements of the different components.

[0073] Control system 614 facilitates driver command of the vehicle using, by way of example, steering system 646 and braking system 648. Steering system 646, which includes a power steering motor, allows for precise directional control, while braking system 648, which may feature disc brakes and an anti-lock braking system (ABS), allows for slowing and stopping.

[0074] Driver Interface and Infotainment 616 supports the driving experience by providing vehicle information and entertainment options via digital displays and multimedia systems. Connectivity features such as Bluetooth and USB further expand functionality.

[0075] Safety systems 618 designed to protect vehicle occupants may include, for example, airbag systems and advanced driver assistance systems (ADAS), which may use an array of sensors, cameras, radar, LiDAR, and / or ultrasonic devices to monitor the vehicle's surroundings, detect potential hazards, and take or suggest corrective actions to prevent accidents and mitigate their effects.

[0076] ADAS can be categorized into different levels of autonomous driving functionality, ranging from Level 0, where a human driver performs all driving tasks, to Level 5, which represents full automation with no human intervention required under any circumstances. Levels 1 and 2 focus on driver assistance and partial automation, respectively, with systems such as adaptive cruise control, lane-keeping assist, and automatic emergency braking assisting but not replacing the driver. Level 3, conditional automation, allows the vehicle to handle all aspects of driving in certain conditions but requires the driver to be ready to take control when necessary. Level 4, high automation, allows the vehicle to operate independently in most scenarios, but still allows for human override.

[0077] Examples of ADAS that contribute to these levels of automation include, but are not limited to, adaptive cruise control, which adjusts the vehicle's speed to maintain a safe distance from the vehicle ahead, lane departure warning systems that alert the driver when the vehicle begins to deviate from its lane, and automated parking systems that assist or take over control of the vehicle during parking maneuvers. More advanced systems contribute to higher levels of automation and include complex algorithms and machine learning capabilities to interpret sensor data, predict the behavior of other road users, and make real-time driving decisions.

[0078] Auxiliary systems 620 assist with vehicle function and occupant comfort, using environmental control and lighting systems as examples. Auxiliary systems 620 may also include windshield wipers, etc.

[0079] As previously mentioned, the systems of 602 are communicatively connected. Communication between the interconnected systems within vehicle 602 is facilitated via a vehicle network architecture, using both hardware and software components to ensure seamless data exchange and coordination. This network architecture may include one or more vehicle communication buses, such as a Controller Area Network (CAN), a Local Interconnect Network (LIN), FlexRay, and Ethernet, which serve as a backbone for in-vehicle communications.

[0080] The Controller Area Network (CAN) bus is a vehicle bus standard designed to allow microcontrollers and devices to communicate with each other within the vehicle 602 without a host computer. Due to its high reliability and immunity to interference, such a network may support control communications between systems such as the battery system 604, the propulsion system 606, and the control system 614. The CAN bus may support messages that ensure real-time control and monitoring of these systems.

[0081] A local interconnect network (LIN) bus may be used for other communications, such as those involving the driver interface and infotainment 616 or auxiliary systems 620. LIN may provide a cost-effective, low-speed serial communication system for connecting intelligent sensors and actuators. It may act as a subnetwork to the CAN bus and handle signals such as switch inputs and actuator outputs.

[0082] FlexRay technology offers higher data rates compared to CAN and LIN, providing the bandwidth necessary for advanced control systems, including those required for autonomous driving functions within safety systems 618. Its deterministic nature and fault tolerance make it suitable for applications requiring precise timing and synchronization, such as coordinating the operation of multiple control units in real time.

[0083] Ethernet, with its high data transfer rates, may be employed, for example, for diagnostic and infotainment applications within the vehicle 602. This Ethernet supports the rapid transfer of large amounts of data, making it well suited for advanced driver assistance systems (ADAS), software updates, and multimedia streaming in the driver interface and infotainment 616 system.

[0084] Software protocols and application programming interfaces (APIs) built on top of these physical layers enable high-level communication and data exchange between systems. These protocols may specify rules for data formatting, timing, and error handling that ensure messages are correctly interpreted and acted upon by the receiving system. example

[0085] Thus, some embodiments may include one or more of the following examples.

[0086] Example 1. A method of providing an electrical connection to a vehicle windshield, the method comprising the steps of preparing a conductive paste for forming a low resistance trace on the windshield, the low resistance trace having a linear resistance in the range of 0.05 to 3 ohms / meter, the conductive paste comprising an inorganic ceramic frit, a silver-based compound, and a liquid vehicle; applying the conductive paste to a glass substrate of the windshield using a screen printing process; drying the applied conductive paste to remove moisture; and firing the glass substrate with the applied conductive paste at a temperature greater than 600°C to harden the conductive paste and form the low resistance trace on the windshield.

[0087] Example 2. The method of example 1, wherein the low resistance trace has a linear resistance in the range of 0.1 to 2 ohms / meter.

[0088] Example 3. The method of example 2, wherein the low resistance trace has a linear resistance in the range of 0.1 to 1 ohms / meter.

[0089] Example 4. The method of example 3, wherein the low resistance trace has a linear resistance of 0.1 ohms / meter.

[0090] Example 5. The method of any one of Examples 1 to 4, wherein the width of the low resistance trace is within the range of 3 to 10 millimeters (mm).

[0091] Example 6. The method of Example 5, where the low resistance trace width is 4 mm.

[0092] Example 7. The method of any one of Examples 1 to 6, wherein the conductive paste further comprises a pigment.

[0093] Example 8. The method of any one of Examples 1 to 7, wherein the conductive paste is prepared by mixing a premixed frit and a silver-based compound with a liquid medium.

[0094] Example 9. The method of any one of Examples 1 to 8, wherein the conductive paste is prepared by mixing the frit in powder form and the silver-based enamel with a liquid medium.

[0095] Example 10. The method of any one of Examples 1 to 9, wherein a conductive paste is applied to the air side of the glass substrate.

[0096] Example 11. The method of any one of Examples 1 to 10, wherein the silver-based compound is included in a silver-based enamel.

[0097] Example 12. The method of any one of Examples 1 to 11, further comprising testing the formed low resistance trace for a linear resistance value.

[0098] Example 13. The method of any one of Examples 1 to 12, further comprising applying a connector on the glass substrate to connect the low resistance trace to an electrical panel, component, or power source of the automobile.

[0099] Example 14. The method of any one of Examples 1 to 13, wherein the low resistance trace is insulated from another low resistance trace by a trace separation distance of at least 5 mm.

[0100] Example 15. The method of any one of Examples 1 to 14, wherein the low resistance traces are printed above or below the layer of black ceramic frit.

[0101] Example 16. A windshield comprising a glass substrate and a low resistance trace screen printed onto the glass substrate using a conductive paste, the low resistance trace having a linear resistance in the range of 0.05 to 3 ohms / meter.

[0102] Example 17. The windshield of Example 16, wherein the low resistance trace has a linear resistance in the range of 0.1 to 2 ohms / meter.

[0103] Example 18. The windshield of Example 17, wherein the low resistance trace has a linear resistance in the range of 0.1 to 1 ohms / meter.

[0104] Example 19. The windshield of Example 18, wherein the low resistance trace has a linear resistance of 0.1 ohms / meter.

[0105] Example 20. The windshield of Example 16, wherein the width of the low resistance trace is within the range of 3 to 10 millimeters (mm).

[0106] Example 21. Windshield of Example 20, with low resistance trace width of 4mm.

[0107] Example 22. The windshield of any one of Examples 16 to 21, further comprising a connector integrated onto the glass substrate for connecting the low resistance traces to an electrical panel, component, or power source in the automobile.

[0108] Example 23. The windshield of any one of Examples 16 to 22, wherein the conductive paste comprises a silver-based compound.

[0109] Example 24. The windshield of any one of Examples 16 to 23, wherein the low resistance trace is insulated from another low resistance trace by a trace separation distance of at least 5 mm.

[0110] Example 25. The windshield of any one of Examples 16 to 24, wherein the low resistance traces are printed above or below the layer of black ceramic frit.

[0111] While examples disclosed herein may relate to automotive windshield technology, other examples and applications are contemplated, and may generally include methods and systems for applying and curing low resistance conductive traces onto other glass surfaces to facilitate the connection of electrical components, and other products may be made by such methods and systems.

[0112] It should be noted that the above description and figures, together with the examples described herein, merely illustrate the principles of the present subject matter and should not be construed as limiting the present subject matter. Accordingly, it is understood that various configurations may be devised that embody the principles of the present subject matter, although not explicitly described or shown herein. Furthermore, all statements herein reciting principles, aspects, and implementations of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.

[0113] It is to be understood that not necessarily all objectives or advantages may be achieved in accordance with any particular example described herein. Thus, for example, those skilled in the art may recognize that some examples may be operated to achieve or optimize one advantage or group of advantages as taught herein without necessarily achieving other objectives or advantages as may be taught or suggested herein.

[0114] All of the processes described herein may be embodied and fully automated via software code modules executed by a computing system including a computer or processor. The code modules may be stored on any type of non-transitory computer-readable medium or other computer storage device. Some or all of the methods may be embodied in dedicated computer hardware.

[0115] Many other variations beyond those described herein will be apparent from this disclosure. For example, depending on the embodiment, some operations, events, or functions of any of the algorithms described herein may be performed in a different order, or may be added, combined, or entirely eliminated (e.g., not all described operations or events may be required to implement an algorithm). Furthermore, in some embodiments, operations or events may be performed simultaneously rather than sequentially, for example, via multithreading, interrupt processing, or multiple processors or processor cores, or other parallel architectures. Furthermore, different tasks or processes may be performed by different machines and / or computing systems that can function together.

[0116] The various illustrative logic blocks and modules described in connection with the examples disclosed herein may be implemented or performed by a machine, such as a processing unit or processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof, designed to perform the functions described herein. A processor may be a microprocessor, but in alternative examples, a processor may be a controller, microcontroller, or state machine, combinations thereof, etc. A processor may include electrical circuitry for processing computer-executable instructions. In some examples, a processor includes an FPGA or other programmable device that performs logical operations without processing computer-executable instructions. A processor may also be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, multiple microprocessors, a microprocessor in combination with a DSP core, or any other such configuration.

[0117] Although described herein primarily in terms of digital technology, a processor may also include primarily analog components. A computing environment may include any type of computer system, including, but not limited to, a computer system based on a microprocessor, a mainframe computer, a digital signal processor, a portable computing device, a device controller, or a computational engine within an appliance, to name a few. Elements of a method, process, routine, or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by a processor device, or a combination of the two. A software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, a hard disk, a removable disk, a CD-ROM, or any other form of non-transitory computer-readable storage medium. A typical storage medium may be coupled to a processor device such that the processor device can read information from, and write information to, the storage medium. Alternatively, the storage medium may be integral to the processor device. The processor device and the storage medium may reside in an ASIC. The ASIC may reside in a user terminal. Alternatively, the processor device and the storage medium may reside as discrete components within a user terminal.

[0118] The processes described herein or illustrated in the figures of this disclosure may be initiated in response to an event, such as a predetermined or dynamically determined schedule, on demand when initiated by a user or system administrator, or in response to some other event. When such processes are initiated, a set of executable program instructions stored on one or more non-transitory computer-readable media (e.g., hard drives, flash memory, removable media, etc.) may be loaded into memory (e.g., RAM) of a server or other computing device. The executable instructions may then be executed by a hardware-based computer processor of the computing device. In some embodiments, such processes, or portions thereof, may be implemented in multiple computing devices and / or multiple processors, either serially or in parallel.

[0119] While the flow diagrams described herein may depict operations as a sequential process, many of the operations may be performed in parallel or simultaneously. Further, the order of operations may be rearranged. A process terminates when its operations are completed. A process may correspond to a method, a procedure, an algorithm, etc. The operations of a method may be performed in whole or in part, may be performed in conjunction with some or all of the operations of other methods, and may be performed by any number of different systems, such as the systems described herein, or any portion thereof, such as a processor included in any of the systems.

[0120] In particular, conditional language such as "can," "could," "might," or "may" is understood within the context in which it is generally used to convey that some examples include certain features, elements, and / or steps, while other examples do not, unless otherwise specified. Thus, such conditional language is generally not intended to imply that the features, elements, and / or steps are somehow exemplary of the examples, or that the examples necessarily include logic for determining whether those features, elements, and / or steps should be included or performed in any particular example, with or without user input or prompting.

[0121] Disjunctive language such as the phrase "at least one of X, Y, or Z" is understood, unless specifically stated otherwise, in the context of otherwise common usage, to state that the item, term, etc., can be either X, Y, or Z, or any combination thereof (e.g., X, Y, and / or Z). Thus, such disjunctive language generally does not and should not imply that at least one of X, at least one of Y, or at least one of Z is required for some instance to exist, respectively.

[0122] Any process descriptions, elements, or blocks in the flow diagrams described herein and / or shown in the accompanying figures should be understood as potentially representing modules, segments, or portions of code containing executable instructions for implementing specific logical functions or elements in the process. As will be appreciated by those skilled in the art, alternatives are included within the scope of the examples described herein, in which, depending on the functionality involved, elements or functions may be omitted or performed in a different order than that shown or described, including substantially simultaneously or in reverse order.

[0123] It should be emphasized that many variations and modifications may be made to the foregoing example, and that the element should be understood as one of other acceptable examples, and all such modifications and variations are intended to be included within the scope of this disclosure.

[0124] Any process descriptions, elements, or blocks in the flow diagrams described herein and / or shown in the accompanying figures should be understood as potentially representing modules, segments, or portions of code containing executable instructions for implementing specific logical functions or elements in the process. As will be appreciated by those skilled in the art, alternative implementations are included within the scope of the examples described herein, in which, depending on the functionality involved, elements or functions may be omitted or performed in a different order than that shown or described, including substantially simultaneously or in reverse order.

[0125] Unless otherwise specified, articles such as "a" or "an" should generally be construed to include one or more listed items. Thus, phrases such as "a device configured to" are intended to include one or more of the listed devices. Also, such one or more listed devices may be collectively configured to perform the stated enumeration. For example, "a processor configured to perform enumerations A, B, and C" may include a first processor configured to perform enumeration A working in conjunction with a second processor configured to perform enumerations B and C.

[0126] It is also understood that one or more of the elements depicted in the drawings / diagrams may be implemented in a more separated or integrated manner as may be useful according to a particular application, or may even be removed or rendered inoperable in particular cases.

Claims

1. 1. A method of providing an electrical connection to a vehicle windshield, comprising: preparing a conductive paste for forming a low resistance trace on the windshield, the low resistance trace having a linear resistance in the range of 0.05 to 3 ohms / meter, the conductive paste including an inorganic ceramic frit, a silver-based compound, and a liquid medium; applying the conductive paste to a glass substrate of the windshield using a screen printing process; drying the applied conductive paste to remove moisture; firing the glass substrate with the applied conductive paste at a temperature above 600°C to harden the conductive paste and form the low resistance traces on the windshield; A method comprising:

2. The method of claim 1 , wherein the low resistance trace has a linear resistance in the range of 0.1 to 2 ohms per meter.

3. The method of claim 2, wherein the low resistance trace has a linear resistance in the range of 0.1 to 1 ohm / meter.

4. The method of claim 3 , wherein the low resistance trace has a linear resistance of 0.1 ohms per meter.

5. The method of claim 1, wherein the low resistance trace has a width in the range of 3 to 10 millimeters (mm).

6. The method of claim 5, wherein the low resistance trace has a width of 4 mm.

7. The method of claim 1 , wherein the conductive paste further comprises a pigment.

8. The method of claim 1 , wherein the conductive paste is prepared by mixing a premixed frit and the silver-based compound with the liquid medium.

9. The method of claim 1 , wherein the conductive paste is prepared by mixing a frit in powder form and a silver-based enamel with the liquid medium.

10. The method of claim 1 , wherein the conductive paste is applied to the air side of the glass substrate.

11. The method of claim 1 , wherein the silver-based compound is contained in a silver-based enamel.

12. The method of claim 1 further comprising testing the formed low resistance traces for linear resistance values.

13. 10. The method of claim 1, further comprising applying a connector on the glass substrate to connect the low resistance traces to an electrical panel, component, or power source of the automobile.

14. 10. The method of claim 1, wherein the low resistance traces are insulated from other low resistance traces by a trace separation distance of at least 5 mm.

15. The method of claim 1 , wherein the low resistance traces are printed above or below a layer of black ceramic frit.

16. A glass substrate; a low resistance trace that is screen printed onto the glass substrate using a conductive paste, the low resistance trace having a linear resistance in the range of 0.05 to 3 ohms per meter; A windshield equipped with

17. 17. The windshield of claim 16, wherein the low resistance traces have a linear resistance in the range of 0.1 to 2 ohms per meter.

18. 18. The windshield of claim 17, wherein the low resistance traces have a linear resistance in the range of 0.1 to 1 ohm / meter.

19. 20. The windshield of claim 18, wherein the low resistance trace has a linear resistance of 0.1 ohms / meter.

20. 17. The windshield of claim 16, wherein the low resistance trace has a width in the range of 3 to 10 millimeters (mm).

21. 21. The windshield of claim 20, wherein the low resistance trace has a width of 4 mm.

22. 17. The windshield of claim 16, further comprising connectors integrated onto the glass substrate for connecting the low resistance traces to an electrical panel, component, or power source in an automobile.

23. 17. The windshield of claim 16, wherein the conductive paste comprises a silver-based compound.

24. 17. The windshield of claim 16, wherein the low resistance traces are insulated from other low resistance traces by trace separation distances of at least 5 mm.

25. 17. The windshield of claim 16, wherein the low resistance traces are printed above or below a layer of black ceramic frit.

Images