Vehicle Glazing Heating Wire Insulation
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Solution Overview
Problem
Existing automotive glazing systems with closely spaced heating wires face issues with short circuits, which can lead to overheating, fire, or explosion, and require costly and difficult wire cutting to prevent short circuits, while also being vulnerable to moisture-induced corrosion.
Innovation Solution
A laminated glazing system with a polymer tape applied between the conductive track and heating wires, preventing short circuits and protecting the conductive track from moisture, eliminating the need for cutting 'shorting' wires and enhancing durability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If heating wires are closely spaced to provide effective heating, then heating efficiency is improved, but the risk of short circuits increases
Solution Approach 1:
A polymer tape is introduced as an intermediary insulating layer between the conductive track and the heating wires. This tape prevents direct electrical contact and short circuits while allowing the closely spaced wire configuration to maintain heating efficiency. The tape is applied to the conductive track before the heating wires are embedded in the interlayer material.
2Reliability
If heating wires are cut to prevent short circuits, then short circuit risk is reduced, but manufacturing complexity and cost increase
Solution Approach 1:
The polymer tape is applied to the conductive track in advance, before the heating wires are embedded. This preliminary insulating action prevents short circuits without requiring subsequent cutting of the wires. The tape remains in place throughout the lamination process, eliminating the need for difficult wire cutting operations.
3Device complexity
If connectors are placed in close proximity for compact design, then device compactness is improved, but short circuit risk increases
Solution Approach 1:
The polymer tape serves as an insulating intermediary between the conductive track and heating wires, enabling connectors to be positioned in close proximity without increasing short circuit risk. The tape ensures electrical isolation even when connectors are arranged compactly at the edges of the glazing.
4Reliability
If polymer tape is applied to insulate conductive track, then short circuit prevention is improved, but manufacturing steps increase
Solution Approach 1:
The application of polymer tape is merged with the existing lamination process. The tape is applied to the conductive track before the interlayer material is positioned, and both are then laminated together in a single heating press operation. This integration adds minimal manufacturing steps while ensuring reliable insulation.
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
The solution effectively prevents short circuits throughout the glazing's lifetime, reduces the risk of overheating and corrosion, and provides a cost-effective and efficient solution for maintaining electrical functionality and safety.
Implementation Method 1
a polymer tape, bonded to the conductive track, eliminates a short circuit effect between the conductive track and the heating wires
Implementation Method 2
The array of heating wires provides resistive heating to the laminated glazing
Data Source
Figure 1~2
Figure 3
AI summary
A laminated glazing (101) for a vehicle comprising an array of heating wires(160), a first busbar (121) and a second busbar (122) in electrical connection with the array of heating wires and arranged such that a voltage applied between the first busbar and the second busbar allows heating of the glazing, and a conductive track (130) electrically connected to the second busbar,further comprising a tape (150) comprising a polymer positioned between the conductive track and the array of heating wires for electrically insulating the conductive track from the array of heating wires.