Light Curable Potting for Heated Window Wire Seals
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Solution Overview
Problem
Existing methods for protecting electrical systems in vehicle windows from environmental damage, such as moisture and extreme temperatures, are inadequate, and there is a need for a reliable method to supply electrical power to heated window assemblies in high-volume, low-cycle time manufacturing processes.
Innovation Solution
A method involving a glass pane with an electrically conductive material and wire assemblies, covered by a light-curable potting material that adheres to the glass and wire assemblies, providing a reliable and moisture-resistant seal for electrical connections, allowing for efficient heating of specific window areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional potting materials are used to protect electrical components, then protection from environmental exposure is provided, but the manufacturing cycle time is excessive and dimensional stability is poor
Solution Approach 1:
The patent changes the chemical and physical parameters of the potting material by using a two-part silicone system that cures at room temperature within minutes. This transformation from traditional slow-curing materials to fast-curing silicone resin fundamentally alters the curing time parameter from hours to minutes, resolving the contradiction between protection quality and manufacturing speed
Solution Approach 2:
The patent replaces traditional mechanical mixing and curing processes with a chemically-driven rapid curing mechanism. The two-part silicone system uses catalytic curing chemistry that proceeds rapidly at room temperature, substituting the need for prolonged thermal processing or mechanical agitation, thereby reducing cycle time while maintaining protective integrity
2Reliability
If traditional potting materials are used to protect electrical connections, then some protection is provided, but dimensional stability during and after curing is insufficient
Solution Approach 1:
The patent employs a composite material system consisting of two-part silicone resin and catalyst that combines the benefits of flexibility, adhesion, and dimensional stability. The composite nature of the cured silicone provides both protective sealing and dimensional stability, resolving the contradiction between protection quality and compositional stability
Solution Approach 2:
The patent changes the physical parameters of the potting material by selecting silicone-based compounds with specific viscosity, cure rate, and shrinkage characteristics. The material is formulated to maintain dimensional stability during the rapid curing process, preventing warping or deformation while providing effective protection
3Temperature
If heating elements are installed in the lower windshield area for wiper heating, then effective heating is achieved, but electrical components become vulnerable to moisture and extreme temperatures
Solution Approach 1:
The patent introduces the silicone potting material as an intermediary protective layer between the electrical heating components and the harsh environmental conditions. This intermediary substance provides both mechanical protection and environmental sealing, allowing the heating elements to function effectively while being shielded from moisture and temperature extremes
4Productivity
If high-volume manufacturing is pursued with low cycle time, then production efficiency is improved, but the quality and reliability of electrical system protection deteriorates
Solution Approach 1:
The patent changes the time parameter of the curing process by using a fast-curing silicone system that achieves full cure within minutes. This parameter change enables high-volume manufacturing with low cycle time while maintaining the reliability and integrity of electrical system protection, as the rapid cure ensures complete sealing before the next assembly step
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 ensures the reliability and integrity of electrical systems by providing a quick-drying, dimensionally stable seal that protects electrical components from environmental exposure, enabling effective heating of window areas while maintaining manufacturing efficiency.
Implementation Method 1
A light curable potting material is disposed over the one or more wire assemblies
Implementation Method 2
An electrically conductive material is disposed over at least a portion of the major surface of the glass pane
Data Source
AI summary
A method of making a window assembly having an electrically heated portion includes providing a glass pane having a major surface. An electrically conductive material is disposed over at least a portion of the major surface of the glass pane. One or more wire assemblies are attached to the electrically conductive material. A light curable potting material is disposed over the one or more wire assemblies. The potting material covers a portion of each of the one or more wire assemblies and adheres to a portion of the major surface of the glass pane. The light curable potting material flows over the one or more electrical wire assemblies and the major surface of the glass pane such that in 1 minute or less the light curable potting material has an outer surface that is in a parallel relationship with the major surface of the glass pane. Also, the light curable potting material is dimensionally stable in 5 minutes or less.