U.S. patent application number 14/321276 was filed with the patent office on 2016-04-21 for window assembly.
The applicant listed for this patent is Pilkington Group Limited. Invention is credited to Charles Sitterlet.
Application Number | 20160107613 14/321276 |
Document ID | / |
Family ID | 55016454 |
Filed Date | 2016-04-21 |
United States Patent
Application |
20160107613 |
Kind Code |
A9 |
Sitterlet; Charles |
April 21, 2016 |
WINDOW ASSEMBLY
Abstract
A window assembly includes a polymeric interlayer provided
between an inner pane of glass and an outer pane of glass. The
inner pane and outer pane each have a first major surface and a
second major surface. The second major surface of the outer pane
and the first major surface of the inner pane face each other. The
window assembly also includes a connector assembly. The connector
assembly has a wire assembly. The wire assembly has a terminal
connector. The terminal connector has a width and a height. The
width is greater than the height. The terminal connector is
attached to a busbar provided on the second major surface of either
the inner pane or the outer pane. A potting layer is provided over
the terminal connector. The potting layer separates the terminal
connector from an electrically conductive portion of a vehicle
adjacent thereto.
Inventors: |
Sitterlet; Charles;
(Northwood, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Pilkington Group Limited |
St. Helens |
|
GB |
|
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20160001744 A1 |
January 7, 2016 |
|
|
Family ID: |
55016454 |
Appl. No.: |
14/321276 |
Filed: |
July 1, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61841993 |
Jul 2, 2013 |
|
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Current U.S.
Class: |
219/203 |
Current CPC
Class: |
B60S 1/026 20130101;
H05B 3/84 20130101; H05B 2203/031 20130101; H05B 2203/013 20130101;
H05B 2203/016 20130101; H05B 3/86 20130101; H01R 4/182
20130101 |
International
Class: |
B60S 1/02 20060101
B60S001/02; H05B 3/86 20060101 H05B003/86; H05B 3/84 20060101
H05B003/84 |
Claims
1. A window assembly, comprising: a polymeric interlayer provided
between an inner pane of glass and an outer pane of glass, the
inner pane and outer pane each have a first major surface and a
second major surface, wherein the second major surface of the outer
pane and the first major surface of the inner pane face each other;
a connector assembly having a wire assembly, the wire assembly
comprising a terminal connector which has a width and a height,
wherein the width is greater than the height and terminal connector
is attached to a busbar provided on the second major surface of
either the inner pane or the outer pane; and a potting layer
provided over the terminal connector, wherein the potting layer
separates the terminal connector from an electrically conductive
portion of a vehicle adjacent thereto.
2. The window assembly defined in claim 1, wherein the potting
layer electrically insulates the terminal connectors from the
conductive portion of the vehicle.
3. The window assembly defined in claim 1, further comprising a
wiper rest area provided on the first major surface of the outer
pane.
4. The window assembly defined in claim 1, wherein the connector
assembly has a plurality of wire assemblies and each wire assembly
comprises a terminal connector, wherein the potting layer is
provided over each terminal connector to separate and insulate the
terminal connectors from the conductive portion of the vehicle
adjacent thereto.
5. The window assembly defined in claim 1, wherein the busbar is
attached to a plurality of electrically conductive traces which
extend along one or more edge portions of either the inner pane or
the outer pane.
6. The window assembly defined in claim 1, wherein the window
assembly is disposed in a body opening of the vehicle and the
conductive portion at least partially defines the body opening.
7. The window assembly defined in claim 1, wherein the terminal
connector comprises a pair of sidewalls which are provided in a
generally parallel relationship with each other.
8. The window assembly defined in claim 5, wherein the busbar and
plurality of electrically conductive traces are formed in a unitary
manner and of silver-containing ceramic frit.
9. The window assembly defined in claim 7, wherein the terminal
connector is substantially rectangular in cross-section.
10. A window assembly, comprising: a polymeric interlayer provided
between an inner pane of glass and an outer pane of glass, the
inner pane and outer pane each have a first major surface and a
second major surface, wherein the second major surface of the outer
pane and the first major surface of the inner pane face each other;
a connector assembly having a wire assembly, the wire assembly
comprising a terminal connector, wherein the terminal connector is
attached to a busbar provided on the second major surface of the
outer pane; and a potting layer provided over the terminal
connector, wherein the potting layer forms an inboard surface which
does not extend beyond the second major surface of the inner
pane.
11. The window assembly defined in claim 10, further comprising a
cutout portion located proximate a peripheral edge of the assembly
and formed in an edge portion of the inner pane and the polymeric
interlayer.
12. The window assembly defined in claim 10, wherein the terminal
connector is of a thickness which is 2.5 mm or less.
13. The window assembly defined in claim 10, wherein the potting
layer is formed of a urethane material.
14. The window assembly defined in claim 10, wherein the potting
layer insulates the terminal connector from an electrically
conductive portion of a vehicle adjacent thereto.
15. The window assembly defined in claim 10, wherein the wire
assembly also comprises an electrically conductive wire which is
mechanically attached to the terminal connector.
16. The window assembly defined in claim 10, wherein the connector
assembly has a plurality of wire assemblies and each wire assembly
comprises a terminal connector, wherein the potting layer is
provided over each terminal connector and each terminal connector
is attached to a busbar formed on the second major surface of the
outer pane.
17. The window assembly defined in claim 10, wherein the inboard
surface formed by the potting layer is aligned with the second
major surface of the inner pane.
18. The window assembly defined in claim 11, further comprising a
polymeric molding member disposed around at least a portion of the
peripheral edge of the assembly.
19. The window assembly defined in claim 11, wherein a portion of
the busbar is located in the cutout portion.
20. The window assembly defined in claim 11, wherein the potting
layer is provided in the cutout portion.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is claiming the benefit, under 35 U.S. C.
119(e), of the provisional application which was granted Ser. No.
61/841,993 filed on Jul. 2, 2013, the entire disclosure of which is
hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a window assembly. More
particularly, the invention relates to a window assembly with a
heated wiper rest area.
[0003] The windows of a vehicle are a prominent feature of the
overall design of the vehicle. Increasingly, the front window or
windshield is a location on which an ever-expanding variety of
electronic equipment and other devices are disposed. Typically,
electricity must be reliably supplied to the equipment and devices
disposed on the windshield to power the aforementioned items. As
such, there is often a balance that must be achieved between the
appearance of the windshield and ensuring that the items disposed
thereon will operate without failure.
[0004] Thus, it would be desirable to provide a windshield which
allows electrical power to be supplied to, for example, a heated
wiper rest area and has a modern, pleasing appearance.
BRIEF SUMMARY OF THE INVENTION
[0005] In an embodiment, a window assembly is provided. The window
assembly comprises a polymeric interlayer provided between an inner
pane of glass and an outer pane of glass. The inner pane and outer
pane each have a first major surface and a second major surface.
The second major surface of the outer pane and the first major
surface of the inner pane face each other. The window assembly also
comprises a connector assembly. The connector assembly has a wire
assembly. The wire assembly comprises a terminal connector. The
terminal connector has a width and a height. The width is greater
than the height. The terminal connector is attached to a busbar
provided on the second major surface of either the inner pane or
the outer pane. A potting layer is provided over the terminal
connector. The potting layer separates the terminal connector from
an electrically conductive portion of a vehicle adjacent
thereto.
[0006] In another embodiment, the window assembly comprises a
polymeric interlayer provided between an inner pane of glass and an
outer pane of glass. The inner pane and outer pane each have a
first major surface and a second major surface. The second major
surface of the outer pane and the first major surface of the inner
pane face each other. The window assembly also comprises a
connector assembly. The connector assembly has a wire assembly. The
wire assembly comprises a terminal connector. The terminal
connector is attached to a busbar provided on the second major
surface of the outer pane. A potting layer is provided over the
terminal connector. The potting layer forms an inboard surface
which does not extend beyond the second major surface of the inner
pane.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The above, as well as other advantages of the present
invention will become readily apparent to those skilled in the art
from the following detailed description when considered in the
light of the accompanying drawings in which:
[0008] FIG. 1 is a partial perspective view of a vehicle depicting
a window assembly in accordance with the invention;
[0009] FIG. 2 is a front view of an embodiment of the window
assembly of FIG. 1;
[0010] FIG. 3 is an enlarged view of a portion of the window
assembly of FIG. 2;
[0011] FIG. 4 is an enlarged view of a portion of the window
assembly of FIG. 3;
[0012] FIG. 5 is a perspective view of a portion of the window
assembly of FIG. 4;
[0013] FIG. 6 is a cross-sectional view of the window assembly of
FIG. 2 taken along line 6-6; and
[0014] FIG. 7 is a cross-sectional view of another embodiment of
the window assembly of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0015] It is to be understood that the invention may assume various
alternative orientations and step sequences, except where expressly
specified to the contrary. It is also to be understood that the
specific articles, assemblies and features illustrated in the
attached drawings, and described in the following specification are
simply exemplary embodiments of the inventive concepts. Hence,
specific dimensions, directions, or other physical characteristics
relating to the embodiments disclosed are not to be considered as
limiting, unless expressly stated otherwise. Also, although they
may not be, like elements in various embodiments described herein
may be commonly referred to with like reference numerals within
this section of the application.
[0016] Referring now to the figures, there is illustrated in FIG. 1
a window assembly 10, 10A. The window assembly 10, 10A will be
described in connection with a vehicle 12. It would be understood
by one of ordinary skill in the art that the assembly described
herein may have applications to on-highway and off-highway
vehicles. Furthermore, it would be understood by one of ordinary
skill in the art that the present invention could have industrial,
locomotive, naval and aerospace applications.
[0017] The window assembly 10, 10A may be installed in any
appropriate body opening of the vehicle 12. It is preferred that
the window assembly 10, 10A is installed in a body opening 32 so as
to be the front window or windshield of the vehicle 12. However, it
should be appreciated that the window assembly could be utilized in
another body opening in the vehicle such as, for example, in a side
or rear opening of the vehicle.
[0018] The window assembly 10, 10A comprises a polymeric interlayer
14 provided between an inner pane of glass 16 and an outer pane of
glass 18. Preferably, the polymeric interlayer 14 is substantially
transparent to visible light. The polymeric interlayer 14 is of or
includes a suitable polymer such as, for example, polyvinyl butyral
(PVB) or another polymer. In certain embodiments like the one shown
in FIG. 7, the polymeric interlayer 14 is provided as a sheet of
material in a shape substantially matched to that of the inner pane
16 and outer pane 18. In other embodiments like the one shown in
FIG. 6, the polymeric interlayer 14 is provided in a shape
substantially matched to that of the inner pane 16.
[0019] To form the window assembly 10, 10A, the inner pane 16 and
outer pane 18 are laminated to each other or are otherwise adhered
together via the polymeric interlayer 14. Lamination processes
known in the art are suitable for adhering the inner pane 16 to the
outer pane 18 via the polymeric interlayer 14 and forming the
window assembly 10, 10A. Generally, such lamination processes will
include inserting the polymeric interlayer 14 between the inner
pane 16 and the outer pane 18 and subjecting the interlayer 14 and
panes 16, 18 to a predetermined temperature and pressure to create
a laminated window assembly 10, 10A. After lamination, it is
preferred that the combined thickness of the polymeric interlayer
14 and the inner pane 16 is 2.7 mm or less. More preferably, the
combined thickness of the polymeric interlayer 14 and the inner
pane 16 is 2.5 mm or less after lamination.
[0020] The inner pane 16 and outer pane 18 each have a peripheral
edge that defines a peripheral edge 30 of the window assembly 10,
10A. The inner pane 16 and outer pane 18 each have a first major
surface 20, 21 and a second major surface 22, 23. Preferably, the
first major surface 21 of the outer pane 18 faces the exterior
environment, the second major surface 22 of the inner pane faces
the interior of the vehicle 12 and the second major surface 23 of
the outer pane 18 and the first major surface 20 of the inner pane
16 face each other.
[0021] When installed, the window assembly 10, 10A is proximate a
windshield wiper system (not depicted). The windshield wiper system
comprises one or more windshield wipers which clean the window
assembly 10, 10A and remove moisture from the assembly to allow the
driver of the vehicle to clearly view the roadway ahead. Under
certain conditions, the windshield wipers help to keep the window
assembly 10, 10A free from ice, slush, and the like. However, under
conditions where ice, slush and the like may form, the windshield
wipers are susceptible to freezing to the first major surface 21 of
the outer pane 18 while in a rest position. Thus, it has been found
to be desirable to heat a portion of the window assembly 10, 10A
where the wipers rest to prevent the wipers from freezing thereto
when the wipers are at rest. Also, it has been found to be
desirable to heat portions of the window assembly 10, 10A where the
wipers deposit ice, slush, and the like after removing the
aforementioned from obstructing the view of the driver. The
aforementioned portions 24 of the window assembly 10, 10A which are
desirable to heat will be referred to hereinafter as the "wiper
rest area."
[0022] The wiper rest area 24 is provided on the first major
surface 21 of the outer pane 18 and in one or more edge portions
26, 26A, 28 of the window assembly 10, 10A so that when the wipers
are at rest or when ice, slush or the like is deposited the
driver's view is only minimally obstructed. For example, the wiper
rest area 24 may comprise a lower edge portion 26, 26A or a side
edge portion 28 of the window assembly 10, 10A. Preferably, the
wiper rest area 24 comprises the side edge portion 28 of the window
assembly 10, 10A adjacent the driver's side of the vehicle. In
another embodiment, the wiper rest area 24 comprises a plurality of
edge portions 26, 26A, 28 of the window assembly 10, 10A. For
example, the wiper rest area 24 may comprise the lower edge portion
26, 26A and side edge portion 28 of the window assembly 10,
10A.
[0023] Heating of the wiper rest area 24 can be accomplished by any
suitable method. An example of a suitable method for heating the
wiper rest area is described in U.S. Pat. No. 6,137,086, which is
incorporated by reference herein in its entirety. However, it is
preferred that heating of the wiper rest area 24 is accomplished by
electrical resistance heating. The wiper rest area 24 can be heated
by providing electrical resistance heating on any of the major
surfaces 20, 21, 22, 23 of the inner pane 16 or the outer pane 18.
However, as illustrated best in FIGS. 6 and 7, it is preferred to
heat the wiper rest area 24 by providing electrical resistance
heating on the second major surface 22, 23 of the of the inner pane
16 or the outer pane 18.
[0024] Preferably, electrical resistance heating of the wiper rest
area 24 is achieved by providing one or more electrically
conductive traces 36 adjacent the wiper rest area 24. The
conductive traces 36 are provided on one of the major surfaces 20,
21, 22, 23 of the inner pane 16 or the outer pane 18 and extend
along one or more edge portions 37, 38 of either the inner pane 16
or the outer pane 18. For example, the conductive traces 36 may
extend along a lower edge portion 37 of the inner pane 16 or the
outer pane 18 or along a driver's side edge portion 38 of the inner
pane 16 or the outer pane 18. Preferably, the conductive traces 36
extend along both the lower edge portion 37 and driver's side edge
portion 38 of the inner pane 16 or the outer pane 18.
[0025] The conductive traces 36 can be formed by a printing
process. However, other processes may be utilized to form the
conductive traces 36 and are suitable for use in forming the window
assembly 10, 10A. Such processes include deletion, sputtering or
silk-screening processes or the like. The conductive traces 36 can
be formed from any material which promotes electrical conductance
and has an electrical resistance so as to generate heat. For
example, the conductive traces 36 may be formed from a
silver-containing ceramic frit.
[0026] The number of conductive traces 36 provided can vary
depending on the amount of heating that is desired and the size of
the wiper rest area 24. Preferably, the conductive traces 36 are
spaced apart from each other and are provided in a grid-like
pattern 39, 40. Depending on the size of the wiper rest area 24, a
plurality of grid-like patterns may be provided. For example, as
shown in FIG. 2, two grid-like patterns 39, 40 are provided to heat
the wiper rest area.
[0027] As shown best in FIGS. 3-4, the conductive traces 36 are
electrically connected at each end to a busbar 41, 42, 43. In
certain embodiments, the conductive traces 36 may be employed in
series. However, in other embodiments, the conductive traces may be
employed in parallel. As illustrated, each busbar 41, 42, 43 may be
provided in a generally perpendicular relationship and formed in a
unitary manner with one or more conductive traces 36.
[0028] Each busbar 41, 42, 43 is electrically conductive. The
busbars 41, 42, 43 can be formed in any manner and from any
material which promotes electrical conductance. In certain
embodiments, the busbars 41, 42, 43 are formed by the same process
and from the same material utilized to form the conductive traces
36. For example, the busbars 41, 42, 43 may be formed by a printing
process and from a silver-containing ceramic frit.
[0029] As illustrated, a plurality of busbars 41, 42, 43 are
provided on the window assembly 10, 10A. The busbars 41, 42, 43 are
provided on the same major surface of the inner pane or the outer
pane that the conductive traces 36 are provided on. Preferably, the
busbars 41, 42, 43 are provided on the second major surface 22, 23
of the inner pane 16 or the outer pane 18. In an embodiment, three
busbars 41, 42, 43 are provided on the second major surface 23 of
the outer pane 18 of the window assembly 10. Alternatively, as
shown best in FIG. 7, three busbars 41, 42, 43 may be disposed on
the second major surface 22 of the inner pane 16 of the window
assembly 10A. In these embodiments, a center busbar 42 is located
between two outer busbars 41, 43. The busbars 41, 42, 43 are
arranged on the second major surface 22, 23 of the inner pane 16 or
the outer pane 18 in a spaced apart and parallel relationship with
each other. The center busbar 42 is electrically connected to each
of the outer busbars 41, 43 in, for example, a series circuit via
the grid-like patterns 39, 40 of the conductive traces 36.
[0030] Each busbar 41, 42, 43 is of a width 44 and a length 45. As
shown best in FIG. 5, the widths 44 of the busbars 41, 42, 43 may
be substantially similar. Preferably, the width 44 of each busbar
41, 42, 43 is selected to minimize the heat generated from the
busbars 41, 42, 43 as electrical current travels through them.
Thus, the width 44 of each busbar 41, 42, 43 is preferably greater
than the widths of the conductive traces 36 connected to it. In
certain embodiments like those illustrated in FIGS. 2-5, each
busbar 41, 42, 43 is of a length 45 such that a first portion 46 of
each busbar 41, 42, 43 is disposed between the second major surface
23 of the outer pane 18 and the polymeric interlayer 14. Also, in
these embodiments, each busbar 41, 42, 43 is of a length 45 such
that a second portion 48 of each busbar 41, 42, 43 extends into a
cutout portion 50 of the window assembly 10. The second portion 48
of each busbar is utilized to electrically connect the busbar 41,
42, 43 to a connector assembly 52.
[0031] As shown best in FIGS. 3-4, the connector assembly 52
comprises a plurality of wire assemblies 54 and a wire connector
56. The wire connector 56 allows a supply (not depicted) of
electrical power to be communicated to the connector assembly 52.
Each wire assembly 54 comprises an electrically conductive wire 58
and a terminal connector 60 attached thereto. On an end, each wire
assembly 54 via the conductive wire 58 is electrically connected to
the wire connector 56. On an opposite end, each wire assembly 54
via the terminal connector 60 is electrically connected to a busbar
41, 42, 43. Electrical power is communicated from the supply to the
wire connector 56 and from the wire connector 56 to the wire
assemblies 54. Electrical power is communicated from the wire
assemblies 54 through the conductive wires 58 and terminal
connectors 60 to the busbars 41, 42, 43 and from the busbars 41,
42, 43 to the conductive traces 36 to heat the wiper rest area 24
to a desired temperature.
[0032] Preferably, each conductive wire 58 is flexible to allow the
wires to extend in and through a space 61 that remains after
installation of the window assembly 10, 10A in the body opening 32
of the vehicle 12. For example, as shown best in FIGS. 6-7, the
conductive wires 58 extend in and through the space 61 around a
molding member 63. In these embodiments, each wire 58 separates a
portion of the molding member 63 from sheet metal 65 which at least
partially defines the body opening 32.
[0033] Preferably, a major portion of each conductive wire 58 is
covered by an insulating sheath 62. The insulating sheath 62
prevents the conductive wire 58 from communicating electrical power
to an undesired portion of the vehicle 12 such as an electrically
conductive portion of the vehicle adjacent the window assembly 10,
10A. A portion of the vehicle which is undesirable to communicate
electrical power to and is adjacent the window assembly 10, 10A
after installation is, for example, the sheet metal 65 which at
least partially defines the vehicle body opening 32. An unsheathed
or exposed portion 64 of each conductive wire 58 is attached in a
robust manner to a terminal connector 60 adjacent an end of the
wire 58. Preferably, the terminal connectors 60 are attached to the
exposed portions 64 of the conductive wires 58 mechanically such
as, for example, by a crimping process. However, other methods of
attaching the terminal connectors 60 to the exposed portions 64 of
the conductive wires 58 may be utilized to form the wire assemblies
54.
[0034] Each terminal connector 60 comprises a cap portion 66. The
cap portion 66 is attached to a pair of sidewalls 68, 70 disposed
on opposite sides thereof. Preferably, the sidewalls 68, 70 are in
a generally parallel relationship with each other. The sidewalls
68, 70 are attached to the cap portion 66 and a base portion 72.
Preferably, the sidewalls 68, 70 are in a generally perpendicular
relationship with the cap portion 66 and the base portion 72. The
exposed portion 64 of the conductive wire 58 separates the
sidewalls 68, 70 from each other and the cap portion 66 from the
base portion 72. Preferably, the cap portion 66 and the base
portion 72 are in a generally parallel relationship with each
other.
[0035] As noted above, each wire assembly 54 is electrically
connected to a busbar 41, 42, 43 via the terminal connector 60. In
order to electrically connect each wire assembly 54 to a busbar 41,
42, 43, the base portion 72 of each terminal connector 60 is
attached to the busbar 41, 42, 43. Preferably, the base portion 72
is attached to the busbar 41, 42, 43 via a soldering method.
Soldering methods known in the art are suitable for attaching a
base portion 72 to a busbar 41, 42, 43.
[0036] The cap portion 66 and base portion 72 of each terminal
connector 60 are of substantially equal lengths and widths.
However, in certain embodiments (not depicted), the base portion is
of a length which is greater than that of the cap portion. In these
embodiments, the additional length of the base portion provides
additional surface area for attaching the base portion to a
busbar.
[0037] In an embodiment, the terminal connectors 60 are
substantially similar having substantially similar or identical
portions and dimensions. Further, in certain embodiments, the
terminal connectors 60 are rectangular in cross-section. Of course,
variations in the processes utilized to form the wire assembly 54
and terminal connector 60 may lead to portions 66, 68, 70, 72 of
the connector 60 being slightly misaligned or deformed. Thus,
"rectangular in cross-section" should be understood to mean that
the terminal connectors 60 could have portions 66, 68, 70, 72
and/or edges which are somewhat rounded and/or be generally
rectangular. Also, it should be appreciated that the terminal
connectors 60 could be of another cross-sectional shape.
[0038] Each terminal connector has a width W and a height or
thickness H. In the embodiments where the terminal connectors 60
are substantially rectangular in cross-section, the width W is the
distance between the outside surfaces of the sidewalls 68, 70 and
the height H is the distance between the outside surface of the cap
portion 66 and the outside surface of the base portion 72. When the
cross-section is not rectangular, especially when the cross-section
is irregular, the "width" is the widest point of the terminal
connector and the "height" is the thickest point of the terminal
connector. Preferably, the width W is greater than the height
H.
[0039] Each terminal connector 60 has a height which allows it to
fit into the space 61 provided between a portion of the window
assembly 10, 10A and the sheet metal 65 at least partially defining
the body opening 32 into which the window assembly 10, 10A is
installed. Preferably, each terminal connector 60 has a height of
2.5 mm or less. More preferably, each terminal connector 60 has a
height of 2.2 mm or less.
[0040] A cylindrical tube member 74 may be disposed around the wire
assemblies 54 to maintain the spacing and orientation of the wires
58 relative to each other. The cylindrical tube member 74 is
provided between and spaced apart from the wire connector 56 and
the terminal connectors 60. Preferably, the cylindrical tube member
74 is made from an insulating material such as, for example, a
polymeric material. However, other insulating materials which can
be provided in a cylindrical shape and offer a degree of resiliency
could also be utilized to form the cylindrical tube member.
[0041] As best shown in FIGS. 6-7, a potting layer 76 is provided
over at least a portion of the busbars 41, 42, 43, each terminal
connector 60 and a portion of each conductive wire 58. The potting
layer 76 separates the terminal connectors 60 from the sheet metal
65 at least partially defining the body opening 32. Advantageously,
the height of each terminal connector 60 is such that the potting
layer 76 can be provided over the terminal connectors 60 at a
thickness which protects the terminal connectors from environmental
damage, electrically insulates the terminal connectors from the
aforementioned sheet metal and provides a window assembly with a
pleasing appearance. Suitable potting layer materials include
acrylics, silicones and urethanes. However, other potting layer
materials are suitable for use in forming the window assembly.
[0042] Preferably, the potting layer 76 is disposed on the second
major surface 22, 23 of the inner pane 16 or the outer pane 18.
When the potting layer 76 is provided on the second major surface
23 of the outer pane 18 as is shown in FIG. 6, the potting layer 76
is provided at a thickness such that it forms an inboard surface 78
which does not extend beyond the second major surface 22 of the
inner pane 16. Thus, the potting layer 76 and the terminal
connectors 60 are of thicknesses that result in a combined
thickness that is less than or equal to the combined thickness of
the polymeric interlayer 14 and inner pane 16. In this embodiment,
it is preferred that the inboard surface 78 formed by the potting
layer 76 is aligned with the second major surface 22 of the inner
pane 16. When the potting layer 76 is provided on the second major
surface 22 of the inner pane 16 as is shown in FIG. 7, the potting
layer 76 forms an inboard surface 80 of the window assembly 10A
which separates a portion of the second major surface 22 of the
inner pane 16 from the sheet metal 65 which partially defines the
vehicle body opening 32 into which the window assembly 10A is
installed.
[0043] As illustrated in FIGS. 2-6, in certain embodiments the
window assembly 10 includes the cutout portion 50. In these
embodiments, each terminal connector 60 is attached to the second
portion 46 of a busbar 41, 42, 43 in the cutout portion 50 and the
potting layer 76 is provided thereover in the cutout portion 50.
The cutout portion 50 is located proximate a peripheral edge 30 of
the window assembly 10. Preferably, the cutout portion 50 is
located in the lower edge portion 26 of the window assembly 10. The
cutout portion 50 is formed in an edge 79, 81 of the inner pane 16
and polymeric interlayer 14 by removing portions of the inner pane
16 and the polymeric interlayer 14.
[0044] The cutout portion 50 can be of any desired shape. For
example, the cutout portion 50 could be of a shape which is
generally circular, hemispherical, oval, rectangular, square,
triangular, or another polygonal shape. However, as shown best in
FIG. 3, it may be preferred that the cutout portion 50 is of a
generally pointed elliptical, partially elliptical or another
generally pointed and/or elliptical shape.
[0045] The molding member 63 is disposed around at least a portion
of the peripheral edge 30 of the window assembly 10, 10A.
Preferably, the molding member 63 is formed from a polymeric
material that can be molded onto or otherwise affixed around the
peripheral edge 30 of the window assembly 10, 10A. The molding
member 63 provides a seal about the body opening 32 of the vehicle
12 that the assembly 10, 10A is installed in. The molding member 63
may be disposed against a water box cover 82 when the window
assembly 10, 10A is installed in the body opening 32. In order to
achieve an aesthetic appearance, there is very little space left
between the molding member 63 and the aforementioned sheet metal
65. Nonetheless, it is desirable to utilize the space 61 to, for
example, provide an electrical connection therethrough.
[0046] In certain embodiments, a spacer 84 may be provided in the
cutout portion 50 along a lower edge 86 of the outer pane 18. The
spacer 84 provides an inboard surface for attaching a portion of
the molding member 63 to the window assembly 10. The spacer 84 is
attached to the window assembly 10 via bonding to the second major
surface 23 of the outer pane 18. Bonding the spacer 84 to the
second major surface 23 of the outer pane 18 can be achieved via an
adhesive or another suitable method.
[0047] From the foregoing detailed description, it will be apparent
that various modifications, additions, and other alternative
embodiments are possible without departing from the true scope and
spirit. The embodiments discussed herein were chosen and described
to provide the best illustration of the principles of the invention
and its practical application to thereby enable one of ordinary
skill in the art to use the invention in various embodiments and
with various modifications as are suited to the particular use
contemplated. As should be appreciated, all such modifications and
variations are within the scope of the invention.
* * * * *