Rear Window Heater Trace Layout Without Busbar Overheating
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Solution Overview
Problem
Conventional slider window assemblies for vehicles, particularly rear openings, face challenges in effectively defogging or defrosting movable window panels regardless of their position, as existing heating elements with busbars can lead to overheating issues due to their width and voltage limitations.
Innovation Solution
The implementation of a rear slider window assembly with single continuous heater lines on each window panel, powered by a higher voltage supply (e.g., 48 volts), eliminating busbars and allowing for efficient defogging or defrosting of both fixed and movable panels whether opened, partially opened, or closed, using flexible connectors and reduced-width connecting portions to prevent overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional heater grids with busbars are used, then heating function is provided, but overheating occurs due to busbar width requirements
Solution Approach 1:
The patent removes the busbar component entirely from the heater grid design. Instead of using traditional busbars to connect heater traces, the invention uses corner connectors that join traces at the corners of the heating element, eliminating the need for wide busbars and the associated overheating problems.
Solution Approach 2:
The patent changes the electrical connection parameters by using higher voltage power supply (e.g., 48V instead of 12V) to reduce current draw. This parameter change allows the use of thinner trace connections without overheating, as power dissipation is reduced at the same heating output level.
2Object-affected harmful factors
If higher voltage power supply is used, then current draw is reduced and overheating is minimized, but power supply complexity increases
Solution Approach 1:
The patent leverages the existing 48V power supply system already present in modern vehicles for other functions (such as electric power steering, brakes, and alternators). By utilizing this existing high-voltage infrastructure, the heater system gains the benefits of reduced current and overheating without adding significant complexity, as the power supply capability already exists in the vehicle.
3Reliability
If movable window panel heating is provided regardless of position, then defogging effectiveness is improved, but electrical connection reliability becomes challenging
Solution Approach 1:
The patent implements a dynamic electrical connection system where the heater grid on the movable window panel can remain powered regardless of its position. The corner connectors and flexible trace design allow the heating element to maintain electrical continuity whether the window is closed, partially open, or fully open, enabling defogging functionality in all positions.
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 solution ensures effective defogging or defrosting of all window panels without overheating, using a higher voltage power supply to reduce current draw and minimize busbar thickness, ensuring reliable operation across various positions of the movable window panel.
Implementation Method 1
a higher voltage power supply (e.g., 48 volts), which powers the continuous heater trace to reduce current draw and minimize overheating of the trace and connecting portions
Data Source
AI summary
A window assembly for a vehicle includes a window panel that has an electrically conductive trace established at a surface of the window panel. The electrically conductive trace includes a single continuous electrically conductive trace that has a positive end for electrically connecting to a positive terminal and a negative end for electrically connecting to a negative terminal. The electrically conductive trace includes a plurality of spaced apart trace segments disposed across the surface of the window panel and a plurality of connecting trace segments that electrically connect adjacent ends of adjacent trace segments, with each connecting trace segment electrically connecting to adjacent ends of only two adjacent trace segments. An electrical connector is connected to the positive and negative terminals at the window panel to provide electrical power to the electrically conductive trace. The provided electrical power may be from a 48 volt power supply of the vehicle.