Method of manufacturing a heated windshield

• US 7,200,921 B2
• Filed: 02/04/2005
• Issued: 04/10/2007
• Est. Priority Date: 02/04/2005
• Status: Expired due to Fees

• Current Assignee: Carlex Glass America LLC (Central Glass Company Limited)
• Original Assignee: Automotive Components Holdings LLC (Ford Motor Company)
• Inventors: Loibl, Joseph M.
• Primary Examiner(s): Tugbang; A. Dexter
• Assistant Examiner(s): NGUYEN, TAI V
• Application Number:
  US11/051,006
• Publication Number:
  US 20060174476A1
• Time in Patent Office: 795 Days
• Field of Search: 296/11, 298/54, 298/16, 296/20, 439/76.2, 219/203, 219/522, 219/541
• US Class Current: 29/611
• CPC Class Codes: B32B 17/10036 comprising two outer glass sheets
• CPC Class Codes: B32B 17/10293 Edge features, e.g. inserts or holes
• CPC Class Codes: B32B 17/10385 for ohmic resistance heating
• CPC Class Codes: B32B 17/10834 using a fluid
• CPC Class Codes: B60J 1/002 with means for clear vision, e.g. anti-frost or defog panes, rain shields window heating in H05B3/84, H05B3/86
• CPC Class Codes: H05B 2203/016 Heaters using particular connecting means
• CPC Class Codes: H05B 2203/017 Manufacturing methods or apparatus for heaters
• CPC Class Codes: H05B 3/84 Heating arrangements specially adapted for transparent or reflecting areas, e.g. for demisting or de-icing windows, mirrors or vehicle windshields
• CPC Class Codes: H05B 3/86 the heating conductors being embedded in the transparent or reflecting material H05B3/845 takes precedence
• CPC Class Codes: Y10T 29/49083 Heater type
• CPC Class Codes: Y10T 29/49099 Coating resistive material on a base
• CPC Class Codes: Y10T 29/49169 Assembling electrical component directly to terminal or elongated conductor
• CPC Class Codes: Y10T 29/49208 by assembling plural parts
• CPC Class Codes: Y10T 29/53513 Means to fasten by deforming

Abstract

A method of making a windshield having first and second outer layers and a conductive bar, an electrical connector, and an intermediate layer positioned between the outer layers. The method includes the step of sinking the conductive bar and the electrical connector into a surface of the intermediate layer so as to be at least substantially flush with the surface. After sinking the conductive bar and the electrical connector into the surface, the first outer layer is engaged with the surface of the intermediate layer. Additionally, the second outer layer is engaged with a second surface of the intermediate layer.

Claims

1. A method of making a windshield having first and second outer layers and a conductive bar, an electrical connector, and an intermediate layer positioned between the first and second outer layers, the method comprising:

heating the electrical connector to a temperature sufficient to soften the intermediate layer;

sinking the conductive bar and the electrical connector into a surface of the intermediate layer such that the conductive bar and the electrical connector are positioned at least substantially flush with the surface;

substantially removing air located between the first outer layer and the surface and between the second outer layer and a second surface;

applying a pressure and a second temperature to the windshield sufficient to cause air located between the first outer layer and the surface and between the second outer layer and the second surface to dissolve into the intermediate layer;

engaging the first outer layer with the surface and the intermediate layer after the step of sinking the conductive bar and the electrical connector into the surface; and

engaging the second outer layer with the second surface of the intermediate layer.

2. A method as in claim 1, wherein the temperature is greater than 250 degrees Fahrenheit.

3. A method as in claim 2, wherein the temperature is less than 350 degrees Fahrenheit.

4. A method as in claim 1, wherein the step of heating the electrical connector occurs before the step of sinking the conductive bar and the electrical connector into the surface.

5. A method as in claim 1, wherein the step of heating the electrical connector occurs substantially simultaneously with the step of sinking the conductive bar and the electrical connector into the surface.

6. A method as in claim 5, further comprising the step of moving a heating element along a length of the electrical connector.

7. A method as in claim 6, wherein the heating element is a soldering iron.

8. A method as in claim 1, wherein the electrical connector includes a heat-protective coating.

9. A method as in claim 8, wherein the heat-protective coating includes polyimide.

10. A method as in claim 1, wherein the windshield further includes a second conductive bar and a conductive wire, the method further comprising:

sinking the second conductive bar into the surface of the intermediate layer such that the second conductive bar is at least substantially flush with the surface; and

engaging the conductive wire with the conductive bar and the second conductive bar such that the conductive wire extends there between.

11. A method of making a windshield having first and second outer layers and a conductive bar, an electrical connector, and an intermediate layer positioned between the first and second outer layers, the method comprising:

heating the electrical connector to a temperature sufficient to soften the intermediate layer;

applying a force to the electrical connector with a component other than the first outer layer;

sinking the conductive bar and the electrical connector into a surface of the intermediate layer;

engaging the first outer layer with the surface the intermediate layer after the step of sinking the conductive bar and the electrical connector into the surface and after the step of heating the electrical connector; and

engaging the second outer layer with a second surface of the intermediate layer.

12. A method as in claim 11, wherein the step substantially of applying the force to the electrical connector occurs substantially simultaneously with the step of sinking the conductive bar and the electrical connector into the surface.

13. A method as in claim 12, further comprising the step of sinking the conductive bar and the electrical connector into the surface of the intermediate layer such that the conductive bar and the electrical connector are positioned substantially with or below the surface.

14. A method as in claim 13, the windshield further including a second conductive bar and a conductive wire, the method further comprising:

sinking the second conductive bar into the surface of the intermediate layer such that the second conductive bar is positioned substantially flush with or below the surface; and

engaging the conductive wire with the conductive bar and the second conductive bar such that the conductive wire extends there between.

15. A method as in claim 14, wherein the force is less than 50 Newtons.

16. A method as in claim 15, wherein the force is less than 25 Newtons.