Patent ID: 7200921

Claim:
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.