Transparent Heating Element with Removable Substrate for Automotive Glass
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Solution Overview
Problem
Existing heating elements for automotive glass struggle with achieving effective heating while maintaining optical clarity, as methods either result in high resistance at low voltages or are visually noticeable due to thick conductive lines, and refractive index differences between films cause distortion.
Innovation Solution
A conductive heating pattern is formed on a transparent substrate without a remaining transparent base, using a bonding film with specific properties and an adhesive film that reduces adhesive strength, allowing for the removal of additional films between substrates, thus preventing view distortions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a transparent conductive oxide film such as ITO is used to form a conductive film on the glass surface, then optical transparency is improved, but heating value at low voltages deteriorates due to relatively high resistance value
Solution Approach 1:
The patent uses a composite structure consisting of a transparent substrate, bonding films, and a metal pattern heating line. This composite approach combines the optical transparency of glass with the electrical conductivity of metal, achieving both transparency and effective heating at low voltages without relying solely on transparent conductive oxide films
Solution Approach 2:
The patent extracts the heating function from the transparent conductive film concept and implements it through a separate metal pattern layer. By separating the heating function into a dedicated metal pattern, the system achieves low-voltage heating capability while maintaining optical transparency through the bonding films and substrate
2Reliability
If a thick tungsten wire is used for heating, then heating value at low voltages is improved, but visual appearance deteriorates due to the tungsten line being visually noticeable
Solution Approach 1:
The patent applies local quality by using a metal pattern with locally optimized thickness and configuration. The metal pattern provides sufficient conductivity for low-voltage heating in specific areas while maintaining thin dimensions (18 micrometers or less) to minimize visual noticeability, achieving both heating performance and aesthetic appearance
Solution Approach 2:
The patent employs thin film technology for the metal pattern layer, creating a heating element that is visually imperceptible. The thin film structure ensures that the heating line does not distort viewed objects while providing adequate electrical conductivity for effective heating at low voltages
3Adaptability or versatility
If a PET film is inserted between two PVB films to form a heating pattern, then heating functionality is improved, but optical performance deteriorates due to distortion from refractive index differences
Solution Approach 1:
The patent extracts the PET film from the final product structure, using it only as a temporary substrate for forming the metal pattern. After the metal pattern is created, the PET film is removed, eliminating the source of refractive index distortion while preserving the heating functionality provided by the metal pattern
Solution Approach 2:
The patent uses bonding films as intermediaries to connect the metal pattern to the PVB films. These bonding films provide the necessary adhesive function without introducing refractive index differences that would cause visual distortion, serving as optimal mediators between the heating element and the glass bonding layers
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 and prevents refractive index-related distortions, providing a heating element with excellent optical properties and heating performance.
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 that reduces adhesive strength, allowing for the removal of additional films between substrates
Data Source
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AI summary
The present specification relates to a heating element and a method for manufacturing the same.