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.

What is claimed is: 
     
         1 . A method of forming a window assembly, comprising:
 providing a terminal connector which has a width and a height, wherein the width is greater than the height;   providing a wire assembly comprising a conductive wire with an unsheathed portion;   connecting the terminal connector to the unsheathed portion of the conductive wire;   providing an inner pane of glass laminated to an outer pane of glass by a polymeric interlayer, 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;   attaching the terminal connector to a busbar provided on the second major surface of either the inner pane or the outer pane; and   applying a potting layer over the terminal connector to electrically insulate the terminal connector.   
     
     
         2 . The method of  claim 1 , wherein the terminal connector is mechanically connected to the unsheathed portion of the conductive wire. 
     
     
         3 . The method of  claim 1 , wherein the terminal connector is crimped to the unsheathed portion of the conductive wire. 
     
     
         4 . The method of  claim 1 , wherein the terminal connector is crimped so that the terminal connector is provided with a substantially rectangular cross-section. 
     
     
         5 . The method of  claim 1 , wherein the terminal connector is soldered to the busbar. 
     
     
         6 . The method of  claim 1 , further comprising forming a plurality of electrically conductive traces that are attached to the busbar. 
     
     
         7 . The method of  claim 6 , wherein the plurality of electrically conductive traces are formed by a printing process. 
     
     
         8 . The window assembly defined in  claim 6 , wherein the busbar and the plurality of electrically conductive traces are formed in a unitary manner and of silver-containing ceramic frit. 
     
     
         9 . 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 electrically insulates the terminal connectors from the conductive portion of a vehicle adjacent thereto.   
     
     
         10 . The window assembly defined in  claim 9 , 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. 
     
     
         11 . The window assembly defined in  claim 9 , 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. 
     
     
         12 . The window assembly defined in  claim 9 , wherein the terminal connector is substantially rectangular in cross-section. 
     
     
         13 . The window assembly defined in  claim 9 , 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. 
     
     
         14 . The window assembly defined in  claim 9 , wherein the terminal connector is of a thickness which is 2.5 mm or less. 
     
     
         15 . The window assembly defined in  claim 14 , wherein the combined thickness of the polymeric interlayer and the inner pane is 2.5 mm or less. 
     
     
         16 . The window assembly defined in  claim 9 , wherein an inboard surface formed by the potting layer is aligned with the second major surface of the inner pane. 
     
     
         17 . A window assembly, comprising:
 an inner pane of glass laminated to 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 wire assembly comprising a wire and a terminal connector, the terminal connector being secured to an exposed portion of the wire, the terminal connector comprising a base portion, a cap portion, and a pair of sidewalls between the base portion and the cap portion, the terminal connector having a width and a height, wherein the width is greater than the height, and the base portion of the terminal connector being secured 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.   
     
     
         18 . The window assembly defined in  claim 17 , wherein the terminal connector is substantially rectangular in cross-section. 
     
     
         19 . The window assembly defined in  claim 17 , wherein the cap portion of the terminal connector is defined by a first portion extending from a first sidewall of the pair of sidewalls to a first portion end and a second portion extending from a second sidewall of the pair of sidewalls to a second portion end, the first portion end being adjacent the second portion end. 
     
     
         20 . The window assembly defined in  claim 19 , wherein the first portion end of the cap portion abuts the second portion end of the cap portion.