Vehicle Window Busbar Coating Process Without High-Temperature Bending
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Solution Overview
Problem
Conventional methods for creating busbars on heatable laminated vehicle windows face challenges such as silver busbar migration issues during thermal bending, leading to uneven heating profiles, residual stress, and potential glass breakage, while also requiring high temperatures that can damage the busbar and affect electrical connections.
Innovation Solution
The process involves applying an electrically conductive material to the coating surface using etching techniques, such as ultrasonic treatment, to form a busbar that connects with underlying conductive layers without heating above 500°C, ensuring a strong and homogeneous electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional thermal bending process is used to create busbars on heatable laminated vehicle windows, then electrical connection is achieved, but silver busbar migration occurs leading to uneven heating profiles and residual stress
Solution Approach 1:
The patent changes the temperature parameter from conventional high-temperature thermal bending (>580°C for soda-lime glass) to a lower temperature range that prevents silver migration while still enabling busbar formation. This parameter change resolves the contradiction by maintaining electrical connection reliability without causing silver busbar migration and uneven heating profiles.
Solution Approach 2:
The patent replaces the conventional thermal bending mechanical process with an alternative busbar creation method that does not rely on high-temperature thermal effects. This substitution eliminates the root cause of silver migration while maintaining the electrical connection function, thereby resolving the contradiction between connection reliability and heating uniformity.
2Ease of manufacture
If high temperature processing is used during thermal bending, then busbar formation is achieved, but glass breakage risk increases and durability decreases
Solution Approach 1:
The patent fundamentally changes the temperature parameter from high-temperature thermal bending to a lower temperature process. This parameter change enables busbar formation while significantly reducing the risk of glass breakage and improving overall glass durability, thus resolving the contradiction between ease of manufacture and reliability.
3Stability of the object's composition
If thermal bending process is used above 580°C, then coating durability is maintained, but busbar material damage occurs and electrical connections are affected
Solution Approach 1:
The patent changes the temperature parameter to a lower range that is sufficient for busbar formation and electrical connection creation without damaging the busbar material or degrading the coating. This parameter change resolves the contradiction by maintaining coating stability while preserving electrical connection quality.
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 method provides a cost-efficient and productive way to create busbars on conductive laminated glazing, ensuring reliable electrical connections and improved durability by avoiding high-temperature processing, which reduces the risk of glass breakage and enhances the homogeneity of the electrical connection.
Implementation Method 1
applying an electrically conductive material to the coating surface using etching techniques
Implementation Method 2
such as ultrasonic treatment
Data Source
AI summary
The present disclosure relates to producing an electrically connected coated substrate. An example method comprises providing a coating on a surface of a substrate; and applying an electrically conductive material to the coating. The electrically conductive material is not heated above 500° C.