Plastic Rear Window Heater with Embedded Grooves
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Solution Overview
Problem
Existing rear window heaters for motor vehicles, especially those made of plastics, face challenges with inadequate protection against mechanical damage and environmental corrosion, particularly when strip conductors are applied on the outer side facing the vehicle environment, which affects their effectiveness in preventing ice buildup.
Innovation Solution
The solution involves embedding strip conductors into grooves within the plastics window pane body, using an electrically conductive paste applied via printing methods, and applying a scratch resistance coating to protect both the conductors and the window pane body, with the grooves angled to minimize reflections and positioned on the outer side to address ice buildup effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If strip conductors are applied onto the outer side of the window pane body facing the vehicle environment, then the heater can effectively prevent ice buildup on the outer surface, but the strip conductors are exposed to mechanical damage and environmental corrosion
Solution Approach 1:
The strip conductors are embedded within grooves formed in the window pane body, placing the conductors inside a protective structure. This nesting approach allows the heaters to remain exposed enough to prevent ice buildup while being protected from mechanical damage and environmental corrosion by the groove structure and overlying hard coat.
Solution Approach 2:
The solution transitions from a two-dimensional surface application to a three-dimensional embedded structure. Grooves are formed in the window pane body to receive the strip conductors, creating a protective recess that shields the conductors while maintaining their functional exposure to the outer surface for ice prevention.
2Object-affected harmful factors
If strip conductors are embedded into grooves of the window pane body, then protection against mechanical damage is improved, but the heater's effectiveness in preventing ice buildup may be reduced
Solution Approach 1:
The grooves are designed with specific geometric characteristics including flank angles of approximately 45° to 65° to optimize both protection and thermal radiation. The local geometry of the grooves is tailored to allow sufficient heat transfer and radiation from the embedded conductors to prevent ice buildup while providing adequate mechanical protection.
3Strength
If a hard coat is applied over the grooves containing strip conductors, then scratch resistance and protection are improved, but the heat transfer efficiency may be reduced
Solution Approach 1:
The hard coat is applied with controlled thickness and material properties to balance protection and thermal performance. The coating parameters are optimized to provide sufficient scratch resistance while maintaining adequate heat transfer efficiency for the heater to function effectively in ice prevention.
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 configuration provides enhanced protection against mechanical damage and environmental influences while ensuring effective ice prevention on the rear window, improving the heater's durability and performance.
Implementation Method 1
the strip conductors are formed from an electrically conductive paste
Implementation Method 2
the window pane body, at the large face that is provided with the grooves, can be provided with a hard coat, in particular with a scratch resistance coating
Data Source
AI summary
A rear window of a motor vehicle includes a window pane body made of plastics and provided with a rear window heater. The window pane body includes grooves at at least one of its two large faces. The grooves are at least partially filled with a strip conductor, wherein the strip conductors form the rear window heater.