Heating Element with Adhesive Film Transfer for Automotive Glass
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Solution Overview
Problem
Existing heating elements for automotive glass struggle with achieving effective heating while maintaining optical transparency, as methods either result in high resistance at low voltages or are visually noticeable due to thick conductive lines, and often cause view distortions from refractive index differences between films.
Innovation Solution
A heating element with a conductive heating pattern formed on an adhesive film, which can be transferred to a transparent substrate without additional films, using an adhesive film with controlled adhesive strength that decreases upon external stimulus, allowing for improved optical properties and simplified processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a transparent conductive oxide film is used to form a heating line on the glass surface, then optical transparency is improved, but heating efficiency at low voltages deteriorates due to relatively high resistance value
Solution Approach 1:
The patent uses a composite structure combining transparent conductive oxide film with metal patterns (tungsten, nickel, or their alloys) to achieve both optical transparency and sufficient heating efficiency. The metal patterns provide low resistance for effective heating, while the transparent conductive oxide film maintains optical clarity, creating a hybrid solution that resolves the contradiction between transparency and heating performance.
2Reliability
If a thick tungsten wire is used to provide sufficient heating value at low voltages, then heating efficiency is improved, but visual appearance deteriorates due to the thick wire being visually noticeable
Solution Approach 1:
The patent employs thin metal patterns (tungsten, nickel, or their alloys) deposited as films rather than thick wires. These thin patterns provide sufficient electrical conductivity for heating efficiency while being visually imperceptible, thus resolving the contradiction between heating performance and aesthetic appearance through dimensional reduction and material thinning.
3Ease of manufacture
If a PET film is inserted between two PVB films to form a heating pattern, then manufacturing flexibility is improved, but optical quality deteriorates due to view distortions from refractive index differences
Solution Approach 1:
The patent removes the PET film from the final product structure, using it only as a temporary substrate for pattern formation during manufacturing. The heating pattern is transferred to the glass surface, and the PET film is eliminated, thereby eliminating the source of optical distortion while having already served its manufacturing purpose. This extraction principle resolves the contradiction between manufacturing ease and optical quality.
4Stability of the object's composition
If additional films are used between transparent substrates to form a heating element, then structural stability is improved, but optical quality deteriorates due to view distortions from refractive index differences
Solution Approach 1:
The patent eliminates additional films from the final product by transferring the heating pattern directly to the glass surface. The adhesive film serves its function during manufacturing to hold the pattern, then is completely removed. This leaves only the heating pattern on the glass without any intermediate films that would cause refractive index mismatches and visual distortions, resolving the contradiction between structural stability during manufacturing and optical quality in the final product.
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 enables efficient heating at low voltages with minimal visual impact, preventing view distortions by eliminating additional films and ensuring the conductive pattern's transparency, thus addressing the limitations of previous technologies.
Implementation Method 1
generating heat from the heating line by applying electricity to both terminals of the heating line, and increasing a temperature of the glass surface therefrom
Implementation Method 2
an adhesive film; and a conductive heating pattern provided on the adhesive film... an adhesive film with controlled adhesive strength that decreases upon external stimulus
Data Source
Figure 1~3
Figure 4
AI summary
The present specification relates to a heating element and a method for manufacturing the same.