Angled Slit Sealing for Heated Laminated Window Conductors
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Solution Overview
Problem
Existing electrically heated laminated windshields face issues with corrosion due to water ingress at the power supply busbars, risk of short circuits from adjacent live and earth busbars, and difficulty in maintaining busbar distance from the glass edge, especially at corners, which complicates the positioning and sealing of electrical connections.
Innovation Solution
A heated laminated window design featuring angled slits in the laminating interlayer for flat electrical conductors to create a water-impermeable seal and facilitate compact turns, allowing busbars to be positioned on opposite sides of the interlayer to avoid short circuits and maintain distance from the glass edge, with conductive ribbons extending outward for easy connection to a power source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If adhesive tape is used to seal between the electrical supply ribbon and the glass, then water ingress is reduced, but the positioning accuracy and time consumption increase
Solution Approach 1:
The angled slit is pre-formed in the laminating interlayer at the correct angle and position before the electrical conductor is installed. This preliminary preparation eliminates the need for time-consuming positioning and adhesive application during assembly, while still providing effective water sealing through the folded conductor design.
Solution Approach 2:
The folded electrical conductor itself acts as the sealing element rather than using separate adhesive tape. The conductor is folded back at the angled slit to create an L-shaped configuration where the folded portion bridges the gap between the slit edges, forming a mechanical seal that prevents water ingress without requiring additional sealing materials.
2Area of stationary object
If live and earth busbars are positioned close together, then the connection area is reduced, but the risk of short circuits increases
Solution Approach 1:
The busbars are arranged in a three-dimensional configuration using the thickness dimension of the laminated window. One busbar is positioned on the outer surface of the laminating interlayer while the other is positioned on the inner surface, allowing them to be close in the plan view but separated in the thickness direction, thus preventing short circuits while minimizing connection area.
Solution Approach 2:
The electrical conductors are nested within the laminating interlayer structure, with the folded portions embedded in the interlayer material. This nesting provides both electrical isolation and mechanical protection, allowing busbars to be positioned close together without short circuit risk.
3Area of stationary object
If busbars are positioned close to the glass edge, then the heated area is maximized, but maintaining minimum distance from the edge becomes difficult
Solution Approach 1:
The angled slits are pre-formed at precise positions and angles in the laminating interlayer before assembly. This preliminary positioning ensures that when the electrical conductors are folded through the slits, they automatically achieve the correct minimum distance from the glass edge, eliminating the need for complex positioning adjustments during manufacturing.
Solution Approach 2:
The angular orientation of the slits creates a geometric constraint that naturally positions the folded busbars at optimal distances from the glass edge. The local geometry of the angled slit provides built-in positioning functionality, ensuring consistent manufacturing precision without requiring additional positioning features or complex assembly procedures.
4Ease of operation
If electrical connections are clustered together, then the connection process is simplified, but the risk of interference between connections increases
Solution Approach 1:
Multiple electrical connections are arranged in the thickness dimension of the laminated window rather than being clustered in a single plane. By positioning connection points at different depths (outer surface vs. inner surface of the laminating interlayer), the design allows connections to be close together in the plan view without interfering with each other electrically or mechanically.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design effectively seals electrical connections against water ingress, prevents short circuits, and allows for efficient busbar positioning close to the windshield periphery, enhancing the heating area while simplifying the connection process.
Implementation Method 1
the thin, flat electrical conductor extends through an angled slit in the laminating interlayer and is folded over at an angle corresponding to the angular relationship of the slit to the thin, flat electrical conductor as it passes through the slit so as to have first and second portions lying on opposite sides of the laminating interlayer
Implementation Method 2
an electrical window heater interposed between the first pane of glass and the laminating interlayer
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A heated laminated window 10 is disclosed having two panes of glass 15, 16 and an embedded window heater 13 which is connected to an external source of electrical power by means of flat electrical conductors 20a, 20b. A plastic laminating interlayer 17 is interposed between and bonded to the two panes of glass 15, 16. The plastic laminating interlayer 17 having at least one angled slit 18, 30 through which a respective one of the electrical conductors 11, 20b extends and is folded over to form a compact corner. The interaction of the electrical conductor 11, 20b with the respective slit 18, 30 locates and retain the respective electrical conductor 11, 20a on the plastic laminating interlayer 17 during assembly and provides a water impermeable seal therebetween after bonding of the heated laminated window has taken place.