Printed Windshield Conductive Traces to Replace Wiring Harnesses

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional wiring harnesses for supplying electrical power to automotive windshields are complex and labor-intensive, complicating vehicle assembly and integration of additional features.

Innovation Solution

Printing low resistance conductive traces directly onto the windshield using a conductive paste, which is then cured to form conductive lines that can carry electrical current, eliminating the need for traditional wiring harnesses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional wiring harnesses are used to supply electrical power to the windshield, then reliable electrical connectivity is achieved, but device complexity and assembly complexity increase significantly

Engineering Contradiction:

Improveelectrical connectivityVSAvoidwiring harness complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the electrical connectivity function directly into the windshield structure by printing conductive traces on the glass surface. This integration eliminates the separate wiring harness system while maintaining reliable electrical connectivity to power heating elements and sensors, thereby reducing device complexity without sacrificing reliability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces the mechanical wiring harness system with a printed electronics approach. Conductive traces are deposited directly onto the windshield using printing techniques, substituting the traditional mechanical cable-based power delivery system with a more integrated and less complex alternative

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Use of energy by moving object

If traditional wiring harnesses are used for power delivery, then electrical power can be supplied to heating elements, but assembly labor and integration complexity increase

Engineering Contradiction:

Improvepower deliveryVSAvoidassembly process

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The patent combines the power delivery function with the windshield manufacturing process itself. Conductive traces are printed directly onto the glass during production, and heating elements are integrated into the same structure, eliminating the need for separate assembly steps involving wiring harness installation and reducing overall assembly labor

Inventive Principle:

Principle #5Merging (Combining)

3Object-affected harmful factors

If high resistance heating elements are used for defrosting, then ice melting functionality is achieved, but energy efficiency decreases

Engineering Contradiction:

Improveice removalVSAvoidenergy efficiency

Core Design Contradiction:

Object-affected harmful factorsVSLoss of energy

Solution Approach 1:

The patent changes the electrical resistance parameter of the heating elements by using conductive ink with optimized conductivity properties. This allows for lower resistance and more efficient energy conversion to heat, improving energy efficiency while maintaining the ice removal functionality. The conductive ink formulation enables precise control of electrical parameters to optimize heating performance

Inventive Principle:

Principle #35Parameter changes

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

Simplifies vehicle assembly, reduces component complexity, and allows for more flexible integration of devices on the windshield, enhancing functionality and reducing manufacturing complexity.

Implementation Method 1

firing the glass substrate with the applied conductive paste at a temperature exceeding 600° C. to cure the conductive paste

Methodology Applied

Scientific EffectFiring: Heat Treatment

Implementation Method 2

Printing low resistance conductive traces directly onto the windshield using a conductive paste, which is then cured to form conductive lines that can carry electrical current

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20250368012A1Printed circuit glass

Publication Date: 2025.12.04 TESLA INC

AI summary

The present disclosure relates to automotive windshield technology, specifically to a method and system for providing electrical connectivity to components integrated within an automotive windshield. The system includes a laminated glass structure with low resistance, highly conductive traces printed directly onto one of the glass surfaces. These conductive traces are designed to carry electrical current to various devices that are either embedded in or attached to the windshield, such as sensors and cameras used in advanced driver assistance systems (ADAS). The conductive traces are created in some examples using a conductive paste applied through a screen printing process and cured to form solid conductive lines. This approach eliminates the need for traditional wiring harnesses, simplifies the vehicle assembly process, reduces manufacturing complexity, and allows for more flexible placement of devices on the windshield.