Wave-Shaped Defogger Wires for Curved Resin Windows
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Resin windows with defogger wires often break due to inability to follow the shape of curved portions during production, leading to uneven heat generation and increased costs.
Innovation Solution
A resin window design featuring wave-shaped defogger wires that follow the curved shape of the window, printed on a film and integrated with the resin glass, reducing wire breakage and heat generation while minimizing the use of conductive paste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the conductive mesh is allowed to follow the shape of the curved portion by placing it in a mold during injection molding, then variations in wire thickness are suppressed and uneven heat generation is reduced, but the defogger wires cannot completely follow the curved shape, causing wire breakage
Solution Approach 1:
The defogger wires are pre-formed with a wave shape before being integrated into the resin window. This preliminary shaping allows the wires to accommodate curved portions of the window without breaking during the molding process, while maintaining uniform thickness throughout the wire structure
Solution Approach 2:
The defogger wires are designed with a wave-shaped curvature rather than a straight configuration. This curvature enables the wires to follow the curved portions of the resin window more effectively, preventing breakage while maintaining consistent wire thickness and uniform heat generation
2Reliability
If the defogger wire is made to completely follow the curved shape of the window, then wire breakage is prevented, but the amount of conductive paste used increases, raising production costs
Solution Approach 1:
The wave-shaped portions of the defogger wire are applied only at specific locations corresponding to curved portions of the resin window, rather than making the entire wire wave-shaped. This partial application prevents wire breakage at critical areas while minimizing the amount of conductive paste used and reducing production costs
3Reliability
If the defogger wire has a wave-shaped portion at the curved portion, then the wire can follow the film stretching and breakage is prevented, but heat generation may occur at the wave-shaped portions
Solution Approach 1:
The wave-shaped portions are designed with specific geometric characteristics and are positioned only at locations corresponding to curved portions of the resin window. This localized design ensures that the wires can follow film stretching without breaking, while the specific wave geometry minimizes unnecessary heat generation and maintains efficient defogging performance
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
Prevents breakage of defogger wires and reduces heat generation, ensuring effective defogging performance while lowering production costs and maintaining a clear field of view.
Implementation Method 1
printing a conductive paste to form a defogger wire on a flat film
Implementation Method 2
stretching the film with the conductive paste printed thereon so as to form a curved portion
Implementation Method 3
a conductive mesh of defogger wires, which extend in the longitudinal and transverse directions, disposed on the resin glass
Data Source
AI summary
A resin window capable of preventing breakage of defogger wires, and a method for producing the same. The resin window includes a plate-like resin glass extending from one end side to the other end side and having a curved portion formed thereon in the extending direction of the resin glass, and a film disposed so as to follow the shape of the resin glass and having a defogger wire extending in the extending direction of the resin glass. When seen in the direction normal to the resin glass, the defogger wire has a wave-shaped portion in at least a portion at a position corresponding to the curved portion.