Ultra-thin laminated glass assembly with electric circuitry

A laminated glass assembly, an electrical assembly for a laminated glass assembly and a method of forming a laminated glass assembly. The laminated glass assembly includes at least an outer glass plate having a first major surface and a second major surface, an inner ultra-thin glass plate having a first major surface and a second major surface and an intermediate film layer situated between the outer glass plate and the inner ultra-thin glass plate. The electrical assembly is positioned between the outer glass plate and the inner ultra-thin glass plate along with a conductive medium to provide a signal path between the laminated glass assembly and vehicular electrical circuitry.

The present specification relates generally to a laminated glass assembly and more specifically to a laminated glass assembly having an ultra-thin glass layer and electrically-conductive circuitry, both to enhance the functionality of the laminated glass assembly.

BACKGROUND

There are numerous applications that utilize a glass window. One notable example is that of a vehicle windshield. A typical modern windshield is a layered assembly that includes optically transparent layers of an outer glass, an inner glass and an intermediate polymeric-based material. Conventional windshield assemblies often include electrically conductive traces that are connected to the glass through soldering, printing or the like, where the thickness of the glass is typically between about 4 and 6 millimeters (mm). Unfortunately, any attempt to reduce the thickness of conventional windshield assemblies causes incompatibilities between the glass and the electrically conductive traces, particularly when using a method of manufacture that involves exposing the layered assembly to one or more of differential pressures and elevated temperature.

SUMMARY

The various aspects disclosed herein provide ways to utilize ultra-thin glass in a laminated glass assembly that also includes electrically conductive features the latter of which provides circuitry for uses such as a communications antenna, a window defroster, a heads-up display (HUD), to impart electrochromic properties to the glass (such as to produce changes in color or opacity), as well as others including to form interface circuitry to integrate with a camera, sensor or other electrical device. Nevertheless, because the use of an ultra-thin layer of glass is very smooth, the authors of the present disclosure discovered that it does not readily lend itself to conventional printing or related deposition approaches that hitherto were used to arrange traditional forms of electrically conductive circuits, traces or patterns. They further discovered that even if a deposited electrical circuit were to be placed on the ultra-thin glass, a subsequent autoclaving or related vacuum-and-temperature environment that is used to fabricate the laminated glass assembly would adversely impact the quality of the finished product. The authors of the present disclosure have further discovered that because improvements in weight, operational efficiency, strength, better environmental protection and other factors are important design considerations for the next generation of automobiles and related vehicles, using a laminated glass assembly with at least one ultra-thin layer along with electrical circuitry that are compatible with conventional autoclaving operations is a key enabler of these vehicles of the future.

As such, and according to an aspect of the present disclosure, a laminated glass assembly includes at least an outer glass plate layer or sheet, an inner ultra-thin glass plate layer or sheet and an intermediate film layer or sheet situated between the outer glass plate and the inner ultra-thin glass plate layers. Further, an electrical assembly is also placed adjacent the inner and outer glass plate layers to form a connector that allows the conveyance of signals between the laminated glass assembly and a vehicular source of electric current. The electrical assembly is configured with flexible, electrically conductive ribbon-based construction for placement relative to the laminated glass assembly in a manner sufficient to replace the previously discussed deposited traces.

Furthermore, according to another aspect of the present disclosure, a method of making a laminated glass assembly includes placing a pair of glass sheets in a mold, the glass sheets comprising an outer layer and an ultra-thin inner layer each of which defines a first major surface and a second major surface. After that, the pair of glass sheets are heated and shaped, as well as placing at least one polymeric intermediate layer between them. In addition, an electrical assembly is placed relative to the shaped pair of glass sheets such that a first portion of the electrical assembly is disposed between the outer layer and the ultra-thin inner layer while a second portion of the electrical assembly is disposed on the second major surface of the ultra-thin inner layer. Furthermore, compression bonding is used on the shaped pair of glass sheets, polymeric intermediate layer and electrical assembly together such that air is substantially removed.

DETAILED DESCRIPTION

According to various aspects of the present disclosure, the combination of ultra-thin glass and novel electrical conductivity improves the technologies of a laminated glass assembly. In particular, various aspects of the present disclosure address the technical problem of achieving lighter-weight glass assemblies with improved electrical connectivity properties while being compatible with best-practice glass assembly techniques. The technical solutions herein bring about several technical effects, including the formation of reduced weight assemblies that exhibit greater resistance to defective attachment between the laminated glass and the electric circuitry.

Within the present disclosure, the term “windshield” and its variants generally refer to an optically transparent glass assembly that is configured for placement within the forward-looking portion of a vehicle such that an operator or passenger is able to see through the windshield along the forward travel path of the vehicle, but also can refer to other vehicular glass assemblies such as rear windows, side windows, roof panels or the like. Whether the term is to be construed as covering merely the forward-looking embodiment in particular or one or more of the other embodiments will be apparent from the context, noting that all such assemblies are deemed to be within the scope of the present disclosure. Also within the present disclosure, the ultra-thin layer of glass being used in a windshield—as well as other glass assemblies such as those in construction or other transportation-related applications—is defined generally as having a thickness of less than about 1.5 mm, and includes specific variants with thickness ranging from between 0.4 and 1.2 mm. In many embodiments, the inner ultra-thin glass plate has a thickness between about 0.4 mm and 1.2 mm, e.g. 0.55 mm, 0.7 mm, 0.8 mm, 0.9 mm, or 1.0 mm, 1.1 mm. In many embodiments, the outer glass plate has a thickness between about 1.5 mm and 6 mm, e.g., 1.8 mm, 2.1 mm, 2.5 mm, 2.8 mm, 3.0 mm, 3.2 mm, 3.5 mm, 3.8 mm, 4.0 mm, 4.5 mm, 4.8 mm, 5.0 mm, 5.5 mm, or 6.0 mm. Despite being thinner than conventional laminated glass (each layer of the conventional laminated glass having a thickness between 2 mm and 6 mm), a windshield or other laminated glass assembly with an ultra-thin layer as disclosed herein possesses desirable mechanical and optical properties, including high strength, low fragility, scratch and break resistance and a high degree of smoothness while maintaining a resistance to heat or pressure-related damage associated with autoclaving and related laminated glass fabrication techniques.

Referring first toFIGS.1,2A and2B, a partial side (that is to say, edge) view illustrates aspects of an ultra-thin laminated glass assembly (also referred to more succinctly as a laminated glass assembly)100according to the present disclosure. As can be seen, the laminated glass assembly100forms a multilayer optically-transparent structure that includes an outer glass plate (or layer)102, an inner ultra-thin glass plate (or layer)104and an intermediate layer106. In the context of a windshield, the outer glass plate102is that which is oriented or exposed to the outside of a corresponding vehicle (not shown). Likewise, the inner ultra-thin glass plate104is that which is oriented or exposed to the interior cabin of the corresponding vehicle. It will be appreciated that these are terms of referential convenience such that the laminated glass assembly100as disclosed herein should not be construed as limited to orienting these plates as “outer” and “inner” unless contextual clarity dictates otherwise. Moreover, the term “plate” when used in conjunction with the outer glass plate102and inner ultra-thin glass plate104is for convenience of discussion; it will be understood that the surface of such “plate” is not required to be planar and may have some curve associated therewith (such as when used as a windshield, back window, side window, roof panel or the like for vehicles, such as for automobiles, industrial vehicles, work vehicles, trains, aircraft or the like). In addition, any spaces depicted in the drawings between the various components are there just for ease of visualization and may or may not be indicative of the actual nature of connection between such components, particularly in an as-fabricated state of the laminated glass assembly100. Furthermore, it will be appreciated that the thicknesses depicted of the various components may be exaggerated for clarity of visualization. In this regard, the various elements and components are not necessarily drawn to scale.

The outer glass plate102includes a first major surface108and a second major surface110. For spatial orientation purposes within the context of an automotive windshield, the first major surface108functions as an outward-looking surface on the outside of the vehicle (not shown) such that it faces—and is be exposed—to the ambient (outside) environment, whereas the second major surface110functions as an inward-looking surface that is not exposed to the ambient environment. By way of example, the outer glass plate102may be made from soda lime glass, aluminosilicate glass, borosilicate glass, polymethyl methacrylate (PMMA), polycarbonate (PC) or the like, and in one embodiment has a thickness between about 1.5 and 6 mm. In a similar way, the inner ultra-thin glass plate104includes a first major surface112and a second major surface114where the former is outward-looking and the latter is inward-looking with the thickness as previously mentioned, although other (that is to say thinner) embodiments of the inner ultra-thin glass plate104are within the scope of the present disclosure. As can be seen, both the second major surface110of the outer glass plate102and the first major surface112of the inner ultra-thin glass plate104face the intermediate layer106that in one form may be an organic polymer film material such as polyvinyl butyral (PVB), a semi-crystalline ionomer-based material (such as SentryGlas® ionoplast or an equivalent), ethylene vinyl acetate (EVA), polyurethane film (PU) or the like. While the intermediate layer106provides some measure of structural integrity, its main purpose is to limit shattering of the laminated glass assembly100upon an impact.

In one form, the outer glass plate102, intermediate layer106and inner ultra-thin glass104are permanently bonded together such that the laminated glass assembly100achieves at least one of sound insulation, heat insulation, infrared protection, or ultraviolet protection. In one form, a multi-step fabrication approach may be used to form the laminated glass assembly100. Such process may include compression bonding that itself may be a multi-step process. For example, a first compression bonding step may include placing the shaped pair of glass sheets102,104, polymeric intermediate layer106and an electrical assembly124(which will be discussed in more detail as follows) together in a vacuum bag (not shown) and then subjecting them to a partially evacuated environment (for example, between about −10 psi and −15 psi) along with elevated temperature (for example, between about 160° F. and 230° F.). Likewise, a second compression bonding step may involve using elevated temperatures (for example, between about 250° F. and 300° F.) and pressures (for example, between about 140 psi and 210 psi). At least this second compression bonding step may be performed in an autoclave (not shown). Significantly, using the electrical assembly124in conjunction with the manufacturing steps as disclosed herein reduces the likelihood of air bubble formation in a region where the electrical assembly124is joined to the remainder of the laminated glass assembly100. In this way, post-welding glass splits are avoided, while the absence of any residual air bubbles is a reliable indication of good adhesion performance of the electrical assembly124to the rest of the laminated glass assembly100.

A conductive medium120resides within the laminated glass assembly100. The conductive medium120may be any copper wire, tungsten wire, aluminum wire, silver wire, printed conductive ink or transparent conductive film made from various materials such as silver or silver alloy or a metal oxide such as indium tin oxide (ITO), fluorine-doped tin oxide (FTO), antimony-doped tin oxide (ATO), aluminum-doped zinc oxide (AZO) or the like. In one form, the conductive medium120may be used to convey electric signals through, along or across the laminated glass assembly100to facilitate certain vehicular-related functionality such as window heating, defrosting, anti-fogging, opacity or color changing, radio-frequency (RF) wireless communication (such as through an antenna), or connectivity to a HUD, camera, sensor or other vehicle electronics. That is, the conductive medium120may be used for any purpose that may require electric signals to operate in or around the laminated glass assembly100, and that need to be conveyed between the laminated glass assembly100and other electronics systems within the vehicle. In the versions shown, the conductive medium120is disposed between a layer of solder130and the second major surface110of the outer glass plate102. By avoiding direct contact between the solder130and the inner ultra-thin glass plate104, the likelihood of cracking or other heat-related problems is reduced.

Various connectivity options and sequences are possible as a way to enable an electrically-conductive path from a terminal126to the conductive medium120. As shown with particularity inFIG.1, the solder130, conductive medium120and a flexible metal ribbon (also called a metal foil, metal sheet or the like)128are secured to one another prior to their placement on the second major surface110of the outer glass plate102. As shown with particularity inFIG.2A, the conductive medium120is first pre-laid on, deposited on or otherwise secured to the outer glass plate102prior to joining to the metal ribbon128with the solder130. As shown with particularity inFIG.2B, the metal ribbon128is first coupled to the conductive medium120through solder130before (or concurrently with) attachment of the conductive medium120to the outer glass plate102. It will be understood that the placement of the joined conductive medium120and metal ribbon128may be in or on the intermediate layer106. Likewise, the order of joining options disclosed herein are merely exemplary, and that other orders or sequences may be used in order to promote ease of manufacture as well as overall structural integrity of the finished laminated glass assembly100.

As can be seen in all ofFIGS.1,2A and2B, the various spaces that may or may not exist between the components are there just for ease of showing the components and how they may be coupled together. Moreover, thicknesses or lengths may be exaggerated or reduced for clarity of discussion. In this regard, elements are not necessarily drawn to scale. As such, the precise configuration of the electrical assembly124and conductive medium120—as well as how the connect to other portions of the laminated glass assembly100—may assume numerous optional forms. In a first optional form, the conductive medium120is formed as a silver pattern directly on the second major surface110of the outer plate102. In a second optional form, the conductive medium120is formed as a conductive wire (using, for example, the aforementioned copper, tungsten, silver, aluminum or the like) that is placed on or otherwise engaged with the intermediate layer106. In a third optional form, the conductive medium120is affixed to a portion of a metal ribbon128along with an insulating outer body142(both of which will be discussed in more detail as follows) in order to perform its electrical connectivity with traces or other vehicular electronic leads. Significantly, the overall thickness of the electrical assembly124is such that when folded over the edge of the laminated glass assembly100, the ratio of such thickness to the radius of curvature of the ensuing fold is such that internal stresses and shear-related deformation are low enough to avoid cracking or related damage to the electrical assembly124as well as to promote a substantially flat fit with the surfaces of the laminated glass assembly100; this last feature is particularly beneficial when subjecting the laminated glass assembly100to autoclaving and related laminated glass-forming operations. Within the present disclosure, the ability of the electrical assembly124to be bent, folded, wrapped or otherwise placed around the edge of the layers of the laminated glass assembly100while preserving its structural integrity (that is to say, substantially free of cracks or other indicia of compromised mechanical properties) along with a substantial degree of flatness (that is to say, without significant surface undulations that otherwise would lead to gaps and related manufacturing defects) means that the electrical assembly124is a flexible electrical assembly.

Referring next toFIGS.3through10in conjunction withFIG.1, the electrical assembly124is used to convey electric current and related signals between vehicle electronics and the laminated glass assembly100. It will be appreciated that although a single electrical assembly124is shown in the figures, multiple electrical assemblies124may be used at various places over the surface of the laminated glass assembly100, depending on the need. It will likewise be appreciated that by configuring the electrical assembly124and laminated glass assembly100to cooperate with the conductive medium120in the manner disclosed herein, enhanced electrical functionality relative to conventional windshield or rear window assemblies is achieved, including the ability to provide a plurality of heating zones with differing power densities some of which may overlap one another. Relatedly, different antenna or related wireless communication circuits may be formed, also with frequency-specific structure formed throughout the windshield or rear window assembly.

As shown with particularity inFIG.5, the electrical assembly124is depicted in isolation as an elongate structure configured as a tongue joint with a first portion124A terminating in a tail at one end and a second portion124B terminating as a head at the opposing end. In one embodiment, the length of the electrical assembly124is about 65 mm total. The electrical assembly124includes numerous components, including the terminal126that is electrically connected to the flexible metal ribbon128. The terminal126is disposed at the head end of the second portion124B. Although shown notionally as having a generally post-like cylindrical shape with a cupped upper portion and curvaceous sidewalls, it will be appreciated that the terminal126may assume any shape (including square or polygonal) to suitable for providing the necessary electrical connectivity with vehicular electronics, such as through a terminal connector and one or more wires, wire assemblies or related structure (none of which are shown). In addition, the terminal126may be configured as a dedicated electronic terminal, a general electronic terminal, a non-contact wireless conductive module or the like. The terminal126is coupled to an enlarged and circular-shaped terminal pad140that forms part of the metal ribbon128, such as through welding or other affixing approaches. In one embodiment, the terminal pad140and significant portions of the length of the metal ribbon128may be encased in the insulating outer body142that may be made from a polymer tape or film such as DuPont™ Kapton® polyimide film. In one form, the insulating outer body142may be sized to define a close conformal fit with the encased metal ribbon128and terminal pad140. At its widest, the insulating outer body142is approximately 16 mm in diameter and narrow down to a width of about 5.5 mm. In one form, the metal sheet128is between about 0.2 and 1 mm thick and has a width of about 1.0 to 5.0 mm, while in a more particular form is about 0.3 mm thick with a width of about 3.5 mm to promote ease of encasement within the insulating outer body142. It will be understood that specific electrical requirements may dictate or enable other thicknesses or widths, and that all such dimensional variants are deemed to be within the scope of the present disclosure.

In one form, the metal ribbon128is made from a tin-plated copper. Further, the metal sheet128can be formed as a unitary piece of single foil, or from multiple pieces of metal strips that are welded (or otherwise coupled) together. As will be understood, by having a foil-based structure, the generally planar opposing first and second major surfaces of the metal ribbon128are of a significantly larger dimension than their respective edgewise minor surfaces, as is the case with the insulating outer body142.

Significantly, the second portion124B of electrical assembly124(which encompasses the head and adjacent region that includes the terminal pad140) couples to the second major surface114of the inner ultra-thin glass plate104via structural bonding tape134(such as 3M™ SBT). In this way, the terminal126and portions of the metal ribbon128and insulating outer body142that are situated directly above (as viewed inFIGS.1,2A and2B) the structural bonding tape134form a secure adhesive connection with the generally planar and underlying second major surface114of the inner ultra-thin glass plate104without having to expose that side of the inner ultra-thin glass plate104to any soldering, welding or related attachment approaches that require the use of significant amounts of heat that could otherwise be damaging to the inner ultra-thin glass plate104. In one form, the adhesive force of the structural bonding tape134may be greater than 80 Newtons (18 pounds). Likewise, the structural bonding tape134may have double-sided adhesive properties.

As shown with particularity inFIGS.1,2A,2B,3,7and10, pressure-sensitive tape136may be disposed along at least a portion of the elongate dimension of the electrical assembly124, particularly along its first portion124A, as well as (depending on the extent of the adhesion needed and as shown inFIG.2B) how it may extend along a substantial entirety of both the first and second portions124A,124B leaving, as shown in an exemplary way inFIG.5, a relatively short exposed portion128A of the metal ribbon128. In one form, the thickness of the pressure-sensitive tape136may be between about 0.1 and 0.4 mm. Through a combination of thin, flexible construction and the use of the pressure-sensitive tape136, the terminal126and a portion of the insulating outer body142and metal ribbon128may be bonded to the second major surface114of the inner ultra-thin glass plate104, while the remainder of the metal ribbon128and the insulating outer body142may be wrapped or folded over an edge of the laminated glass assembly100and extend to be sandwiched between the first major surface112of the inner ultra-thin glass plate104and one or the other of the intermediate layer106and the outer glass plate102. Upon such folding, the electrical assembly124may be attached such that the second portion124B and terminal126face inward (that is to say, toward a vehicular cabin when the laminated glass assembly100is configured as an automotive windshield) while the first portion124A and the region containing the solder130face outward (that is to say, toward an ambient external environment when the laminated glass assembly100is configured as an automotive windshield) that, as noted elsewhere, is away from the inner ultra-thin glass plate104. In one form, other adhesives, such as structural adhesive, PU-based adhesive, hot-melt adhesive, quick-drying adhesive, epoxy resin, light-curing structural adhesive, anaerobic adhesive or combinations thereof may be used in place of or in conjunction with the pressure-sensitive tape136, and that all such variants are within the scope of the present disclosure.

Referring with particularity toFIG.4, an edge perspective view of the electrical assembly124being coupled to a conductive medium120is shown, where—among other components—the outer glass plate102, inner ultra-thin glass plate104and intermediate layer106have been omitted for ease of viewing. As discussed herein, the conductive medium120may correspond to windshield-mounted or windshield-integrated electrical circuitry that may be used for conveying electrical signals between the laminated glass assembly100and vehicle electronics (not shown) for the purpose of performing heating, defrosting, anti-fogging, selective opacity or color changing, receiving wireless signals, for implementing a HUD, for connecting to a camera, sensor or other vehicular electronic equipment. In one form, the conductive medium120may be configured as a pre-laid metal wire (made from, for example, copper, tungsten or the like), while in another, as a conductive trace (made from a metal-based paste, conductive ink or the like, using silver, silver alloy or related conductive material) that can be deposited on or otherwise applied to an appropriate surface of one of the glass layers. As shown, the conductive medium120may be connected to the electrical assembly124at the exposed portion128A of the metal ribbon128through a solder deposit148at a receiving pad150. Significantly, the elongate nature of the electrical assembly124allows for the receiving pad150of the conductive medium120to be placed farther from an edge of the laminated glass assembly100. While the precise location of a welding or related connecting point between the electrical assembly124and the one or more layers of the laminated glass assembly100can vary depending upon the end-use, in a practical sense, the location of the welding point may be somewhere between about 10 and 20 mm from the edge of the glass layer. This placement, along with the low-temperature methods of adhesion between the electrical assembly124and one or more of the glass or polymer layers that make up the bulk of the laminated glass assembly100, will help reduce bubbling, cracking, splintering or other possible defects that may arise out of welding or other parts of the laminate manufacturing process.

Referring again toFIG.5, a top view of one embodiment of the tongue joint that makes up a portion of the electrical assembly124is illustrated. Certain representative dimensions of this embodiment are discussed next. The tongue joint has an overall length LT (which, as previously stated, may be about 65 mm), while at the widest part as defined by the terminal pad140(and insulating outer body142) defines a generally circular shape having a diameter of approximately 16 mm, also as previously indicated. A cutout144is formed in the insulating outer body142that encases the metal ribbon128to allow for direct electrical contact between the metal ribbon128and the terminal126. For instance, an 11 mm circular cutout can be provided for the terminal126. A midsection124C defines a generally rectangular portion of the electrical assembly124that is situated between the head and tail and that bridges one or both of the first and second portions124A,124B. A portion L1of the length of the midsection124C may be configured to have an optional peel tab that can act as—or otherwise be cooperative with—a release liner124D that upon removal would expose underlying adhesive such as the pressure-sensitive tape136that is adhered to the reverse of the metal ribbon128as shown inFIGS.1,2A and2B. The release liner124D is presently shown with a discrete length L1through the presence of intermittent laterally-extending die cuts; it will be appreciated that their number and frequency may be dictated by the amount of exposure of the pressure-sensitive tape136(and consequent adhesive bonding between the electrical assembly124and one or more facingly-adjacent surfaces of the laminated glass assembly100) is needed. Another portion L2of the length of the midsection124C is configured such that a common edge forms a divider124E that defines the location along the electrical assembly124that is adjacent the edge (rather than one of the major surfaces) of the laminated glass assembly100upon electrical assembly124folding, such as shown inFIG.3. In such case, upon folding and attachment to the laminated glass assembly100, the portion of the midsection124C corresponding to L1would be seen as being disposed directly over the portion of the midsection124C corresponding to L2when being viewed from a passenger cabin of a vehicle. As such, divider124E may make it easy for a fabrication or installer to align the electrical assembly124with the laminated glass assembly100. It will be appreciated that the divider124E can be physical or conceptual to define a foldover point124F (as shown inFIGS.3and4) that corresponds to the location where the electrical assembly124is wrapped around the edge of the laminated glass assembly100. In circumstances where the divider124E is a physical embodiment, it too can be formed by known cutting approaches, such as by die cutting or the like.

In one form, the first length L1can be approximately 9 mm, while the second length L2can be approximately 6 to 8 mm. The tail at the first portion124A is illustrated in two segments, designated by length L3and length L4where it will be appreciated that L3generally corresponds to the exposed portion128A of the metal ribbon128and L4generally corresponds to a solder deposit (such as solder130) that in one form may be about 0.2 mm thick. In one form, a combined length L3+L4of the tail is approximately 10.5 mm, with L3being approximately 4.1 mm and L4being approximately 6.4 mm. As the tail corresponds to a portion of the metal ribbon128that is not sheathed in the insulating outer body142, its width (which is approximately 3.5 mm in one form) is more narrow than the midsection124C and second portion124B.

Referring with particularity toFIG.6, a bottom view of the embodiment of the tongue joint that makes up a portion of the electrical assembly124fromFIG.5is illustrated. In an example configuration, the back of the terminal pad140defines a generally circular shape that is covered with a layer of tape, such as the previously-discussed structural bonding tape134. In an example configuration, a length L5of the remote end of the second portion124B that encompasses the terminal pad140and structural bonding tape134, including a neck portion that shoulders down into the midsection124C, can be approximately 20 mm. Lengths L6and L7correspond to the midsection124C where L6may have a length of approximately 24 to 26 mm and L7of about 9 mm that can be covered by a peel tab similar to the aforementioned peel tab124D, release liner or other means to protect an underlying adhesive until use. The length L8is analogous to that of L3+L4ofFIG.5, specifically 10.5 mm in length and forms the exposed portion128A of the remote tail end of metal ribbon128.

Referring with particularity toFIG.7, an edge cutaway view shows the cooperation of the various components that correspond to the lengths L1through L8ofFIGS.5and6. As can be seen, the metal ribbon128(shown with diagonal hatching) extends along almost the entirety of the length of the electrical assembly124. The terminal126is situated in the circular cutout that is formed in the vertical hatched portion that represents the insulating outer body142. In this way, the terminal126can be attached to the metal ribbon128at the head end of the second portion124B. As shown, such attachment may be through welding, soldering or a related connection mechanism127that ensures electrical continuity between the terminal126and the metal ribbon128. The structural bonding tape134is shown in diagonal hatch at the head end of the second portion124B underneath the metal ribbon128. In looking at the obverse of the electrical assembly124, the peel tab124D (with accompanying release layer) is placed on an upper surface of a portion of the length of the insulating outer body142, while an adhesive layer as previously described is disposed between the peel tab124D and the insulating outer body142. Although not shown, as previously discussed in conjunction with the peel tab124D, in another form the peel tab124D may be made to be coplanar with a top surface of the insulating outer body142such that upon removal of the peel tab124D, a portion of the metal ribbon128becomes exposed. A layer of solder130may be disposed on the metal ribbon at the tail end of the first portion124A. As previously discussed, upon folding the electrical assembly124upon itself at the foldover point124F that is somewhere along the first portion124A or midsection124C, the resulting shape causes the solder130to face in a direction opposite of the terminal126and the inner ultra-thin glass plate104; in this way, upon attachment of the electrical assembly124to the various layers of the laminated glass assembly100, the solder130may be placed in facingly-adjacent contact with the conductive medium120or outer glass plate102ofFIGS.1,2A and2B. In looking at the reverse of the electrical assembly124, the structural bonding tape134is generally coplanar with the lower surface of the insulating outer body142as well as a layer of adhesive (such as the aforementioned pressure-sensitive tape136). A peel tab (such as one similar to the aforementioned peel tab124D) may disposed on top of the adhesive such that upon its removal, the adhesive becomes exposed.

Although not shown, it will be appreciated that other shapes and sizes of the electrical assembly124may be formed, and that all are within the scope of the present disclosure. For example, in one embodiment the overall length LT may be approximately 91 mm, while in another example there is no taper when extending from the second portion124B to the first portion124A such that the width W remains at a constant 16 mm. Similarly, the various lengths L1through L8may have different dimensions, depending on the way the present embodiment is secured to the remainder of the laminated glass assembly100. In a similar way, the electrical assembly124may be conceptually divided into several regions, including a first region124A, a second region124B and a midsection124C where one or more of the regions may include the selective use of an adhesive (such as the previously-discussed pressure-sensitive tape136) and, if needed, release layer, peel tab124D or the like.

Within the present disclosure, the use of the prepositional phrase “at least one of” is deemed to be an open-ended expression that has both conjunctive and disjunctive attributes. For example, a claim that states “at least one of A, B and C” (where A, B and C are definite or indefinite articles that are the referents of the prepositional phrase) means A alone, B alone, C alone, A and B together, A and C together, B and C together or A, B and C together.

Within the present disclosure, the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 USC 112(f) unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure. To the extent that any means or step plus function elements may now or in the future be included in the claims, any such corresponding structures, materials, acts and equivalents of all means or step plus function elements are intended to include any structure, material or act for performing the function in combination with other claimed elements as specifically claimed.

The description of the present disclosure has been presented for purposes of illustration only and as such not intended to be exhaustive or limited. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the present disclosure. Aspects of the disclosure were chosen and described in order to best explain the principles of the disclosed subject matter and the practical application, and to enable others of ordinary skill in the art to understand the same for various embodiments with various modifications as are suited to the particular use contemplated.