Panel assembly for vehicle and method of manufacturing the same

Abstract

The invention relates to a panel assembly for a vehicle, the panel assembly comprising a composite laminated panel (10) having an inner panel (1), an outer panel (3) adjacent to the inner panel (1), and a thermoplastic intermediate panel (2) bonding the inner and outer panels (1, 3) together. A through-hole (16) extends between an inner surface (12) of the inner panel (1) and an outer surface (14) of the outer panel (3) on the laminated panel (10), and a gasket (20) provides a seal between the through-hole (16) and a sensor (40) located within the through-hole (16), the gasket surrounding the sensor (40) in a manner that fixes the sensor (40) to the laminated panel (10).

Description

TECHNICAL FIELD

[0001] The present invention relates to a laminated panel assembly with a thermoplastic interlayer, in particular to a vehicle glazing and a method of manufacturing thereof. BACKGROUND

[0002] A vehicle glazing is a laminated panel structure with an outer panel and an inner panel adjacent to each other, and a thermoplastic interlayer comprising PVB that bonds the inner panel and the outer panel together. In a windshield, the composite panel is in a trapezoidal shape.

[0003] Advanced Driver Assistance Systems (ADAS) and forward looking sensors are typically installed near the central area close to the upper edge, facing the inner surface of the inner panel, this area is commonly referred to as the sensor window. The sensor window is the area through which electromagnetic waves pass from the inside of the windshield and are detected by the sensor. Measures are taken to prevent the laminated panel from distorting the sensor input signal. One known measure is to make a cut in the inner panel at the sensor window and to reduce the thickness of the panel section for the sensor signal.

[0004] WO2021041839 discloses a glass for use in a motor vehicle that contains a camera responsive to infrared electromagnetic waves having a wavelength greater than 20 microns. The glass has an outer surface and an inner surface, the inner surface is defined by a first panel that is disposed opposite the outer surface on the first panel. The first panel has a peripheral edge that defines an outer periphery of the first panel. The first panel further includes an opening between the inner surface and the outer surface of the first panel within the peripheral edge of the first panel; a second panel defines an outer surface and an inner surface, and the inner surface of the second panel is disposed opposite the outer surface of the second panel. The orientation of the second panel relative to the first panel is such that the inner surface of the second panel faces the inner surface of the first transparent layer. At least a portion of the second panel covers the opening of the first panel, and the material of the second panel is selected from a group comprising zinc sulfide and polycarbonate. SUMMARY

[0005] It is an object of the present invention to improve the sensor sensitivity in a laminated panel with a thermoplastic interlayer, in particular in a vehicle windshield.

[0006] To achieve the above objectives, the present invention relates to a panel assembly for a vehicle, comprising a composite laminated panel including an inner panel, an outer panel adjacent to the inner panel, and a thermoplastic intermediate panel bonding the inner and outer panels together. The panel assembly includes a through-hole extending in the laminated panel between the inner surface of the inner panel and the outer surface of the outer panel; the panel assembly also includes a gasket sealing the through-hole, and a sensor positioned within the through-hole by surrounding and securing the sensor to the laminated panel with the gasket. The gasket prevents wind, water, or other external factors from entering through the through-hole by surrounding the sensor. Because the sensor is accessible to the external environment through the through-hole in the laminated panel, any potential for distortion or attenuation / reduction in the signals (such as radiated or electromagnetic signals) transmitted to the sensor by the laminated panel is eliminated. The sensor may have inherent elements, such as lenses or protective glass, that do not limit its acquisition of internal and external signals.

[0007] Preferably, the housing is directly supported on the laminated panel by a gasket and at least partially surrounds the sensor. The housing is supported by the gasket, eliminating the need for additional support structures in the laminated panel that would reduce the field of view for carrying the sensor. In possible configurations, the housing can be adjusted within the through-hole to align with the inner and outer surfaces, or partially extend outward from the inner and / or outer surfaces. The housing can be a tubular structure, a shape matching the through-hole, have different cross-sections like a ring, or a tray-like structure with raised edges.

[0008] Preferably, the gasket is made of a flexible material. Gaskets made of flexible materials reduce the transmission of vibrations along the road to the sensor, thereby improving the accuracy of sensor signal readings.

[0009] Preferably, the front end of the housing is aligned with the outer surface of the outer panel. In this case, the housing will not protrude outward after the laminated panel is installed on the vehicle, thus not adversely affecting the vehicle's aerodynamic performance.

[0010] Preferably, the housing is made of a stiff material. This protects the sensor from impacts, both inside and outside the vehicle, and transfers the sensor's weight directly to the gasket. Thus, the sensor can be supported by the housing using only the gasket, without the need for additional supports.

[0011] Preferably, the housing includes a guide structure, particularly threads, on its inner wall, and the outer wall of the sensor directly engages with this guide structure in a leak-proof manner. This allows the sensor to be easily installed and removed within the laminated panel on which the housing is located. The threads allow for precise adjustment of the sensor's linear distance within the housing. In possible configurations, sliders or other different assembly systems can be used instead of threads.

[0012] Preferably, the rear portion of the housing extends inwardly from the inner surface by a distance equal to the thickness of the laminated panel supported by the gasket at the front portion. In this case, the inwardly extending portion allows the housing to extend so that a longer sensor such as a video camera can be disposed in the laminated panel without causing axial misalignment.

[0013] Preferably, the housing is coaxially aligned with the sensor. This allows the sensor to be installed in the laminated panel (e.g. a vehicle windshield) in a simple forward motion.

[0014] Preferably, the gasket comprises polyurethane. Polyurethane is resistant to the effects of external elements and sufficiently attenuates vibrations in the laminated panel. Moreover, the application and expansion of polyurethane between the through hole and the housing during the installation process can completely fill the gap, thereby facilitating the installation of the housing in the laminated panel in the correct position. This eliminates the need to provide mounting elements such as flange applications on the front and rear surfaces of the laminated glass. In possible configurations, different flexible materials such as silicone or rubber can be used instead of polyurethane.

[0015] Preferably, the inner and outer panels are made of a glass material. This meets vehicle standards and allows the laminated panel to be used as a front or rear windshield of a vehicle.

[0016] Preferably, the intermediate panel is made of a PVB material and is directly adjacent to the inner and outer panels. This ensures that the vehicle glass meets vehicle standards.

[0017] Preferably, the hole is disposed near the central axis of the laminated glass and adjacent to the upper edge. This forms a sensor window, providing a laminated panel that meets vehicle interior design standards and allows the sensor to have a wider field of view when disposed near the upper edge of the vehicle.

[0018] Preferably, the sensor has a video camera. The video camera can capture images above the laminated panel without being affected by the structure of the laminated panel (e.g. coatings and refractive indices that reduce optical transmittance). This achieves an ideal optical system in terms of modulation transfer function.

[0019] A preferred application comprises the steps of obtaining a laminated glass by providing an inner panel, an intermediate panel and an upper panel directly adjacent to each other in sequence, longitudinally cutting the laminated glass to form a hole, and providing a ring-shaped gasket in the hole. In possible configurations, the hole can have a closed geometry (e.g. circular, triangular, trapezoidal, oval, etc.) and be kept at a distance from the upper edge of the laminated glass; or, preferably, an open geometry towards the upper edge can be used.

[0020] A preferred application includes the step of mounting the housing from the outer wall to the inner wall of the grommet. The housing can be placed with the grommet in place, or the grommet can be applied after the housing is secured within the hole. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1 Front view of a representative laminated panel according to the present application.

[0022] Figure 2 Front view of a representative laminated panel according to the present application. Figure 1 Application of vehicle glass with mounted camera shown in cross section along line A-A.

[0023] Figure 3 Front view of an alternative configuration of a laminated panel according to the present application including a hole of different geometry. DETAILED DESCRIPTION

[0024] This detailed description in intended to aid those skilled in the art of understanding, but not to place any limitations on the application.

[0025] Figure 1 Front view of a vehicle windshield shown from the perspective of the vehicle interior. The windshield includes a laminated panel (10) having an inner panel (1) made of glass with a thickness of 0.7-2.5 mm. The inner panel (1) is trapezoidal in shape and its inner surface (12) is concavely curved. A circular through hole (16) is provided on the laminated panel (10). A ring-shaped grommet (20) made of polyurethane material extends radially inward along the circumference of the through hole (16) and is mounted to the laminated panel (10). A coaxial plastic cylindrical housing (30) is inserted within the grommet (20).

[0026] Figure 2A cross-sectional view of the top portion of a vehicle windshield, called the sensor window, is shown. The inner panel (1) is similar in size and slope to the outer panel (3) and is connected together by an intermediate panel (2) made of PVB material to form a laminated panel (10). The laminated panel (10) is subjected to a bending process at a temperature between 500 and 700 degrees Celsius and is cooled to form a curved shape. A through hole (16) is cut in the sensor window on the laminated panel (10) using a die blade or, alternatively, using a water jet or a laser beam (not shown). The through hole (16) is aligned with a vertical central axis (M) that passes through the center of the laminated panel (10). A coaxial housing (30) is inserted at the center of the through hole (16), and a front portion (35) of the housing (30) is aligned at its outer end with an outer surface (14) of the outer panel (3). In this case, an extruded polyurethane material is used to fill the space between the front portion (35) of the housing (30) and the through hole (16) itself, which remains inside the through hole (16), in a leak-proof manner, thus forming a gasket (20). The gasket (20) is fitted so that it completely surrounds the through hole (16) from a radially outer wall (22). On the other hand, the gasket (20) secures the housing (30) by extruding radially inward from an opposite inner wall (24) at the front portion (35). Thus, the through hole (16), the gasket (20), and the housing (30) are coaxially secured in the laminated panel (10). Due to the flexible polyurethane material of the gasket (20) and the curved structure of the laminated panel (10) (not shown in the figure), a radial difference between the inner and outer edges of the through hole (16) can be compensated for to keep the extension axis of the housing (30) aligned with the coaxiality of the through hole (16). An inner wall (34) of the housing (30), opposite the outer surface (32) where the housing (30) rests on the gasket (20), surrounds a cylindrical void and is provided with a full thread. In this way, a sensor (40) with an appropriate threaded form on its outer wall (42) is rotated along the through hole axis and mounted inside the housing (30). By means of the threaded structure, the sensor (40) can be rotated so that its flat front end (44) is aligned in a shape-fitting manner with the outer surface (14) of the outer panel (3). When the sensor (40) is mounted to the housing (30), the weight of the sensor (40) at the front portion (35) creates a moment of force that, especially when the vehicle is in motion, can create a dynamic load along the through hole (16) with the vibrations in the laminated panel (10). Since the gasket (20) is made of a flexible material, it attenuates the vibrations of the laminated panel (10) that directly support the housing (30) with the sensor (40), thus reducing the wavelength of the dynamic load. This prevents the weight of the housing (30) together with the sensor (40) from causing cracks in the inner and outer panels (1, 3) made of glass material at the inner wall of the through hole (16).When the sensor (40) is completely placed in the housing (30), its front end (44) is not in any way obstructed by the laminated panel (10). Thus, the front end (44) of the sensor (40) facing forward is directly open to the outside environment. In this case, factors such as light refraction or the presence of fog, raindrops, etc. on the laminated panel (10) cannot hinder the radiation from entering at the front end (44). The lens (not shown) provided at the front end of the sensor (40) can be made of a different material than the outer panel (3) and this material is more suitable for the type of sensor (40) in terms of electromagnetic wave transmission and modulation transfer function values. This ensures high optical performance for the sensor (40), which is particularly advantageous for sensors used in autonomous vehicles, enabling the sensor to provide more accurate information to the vehicle control system and improving driving safety.

[0027] Figure 3 The laminated panel (10) used as a vehicle windshield and having holes (16) of different geometries is shown from the perspective of the inner surface (12) of the inner panel (1). In the laminated panel (10), the structure of the hole (16) near the upper edge (11) and aligned with the central axis (M) can be circular, vertically or horizontally oval, vertically trapezoidal, or extend in the shape of a horizontal or vertical rectangle. In addition, holes (16) of different geometries can also be used, such as a triangle or a rounded rectangle with one side open towards the upper edge (11). The gasket (20) is applied to the hole (16) in a leak-proof manner, completely filling the geometry of the hole (16) and wrapping around the housing (30).

[0028] Reference signs

[0029] 1 inner panel; 30 housing

[0030] 2 intermediate panel; 32 outer surface

[0031] 3 outer panel; 34 inner wall

[0032] 10 laminated panel; 35 front portion

[0033] 11 upper edge; 40 sensor

[0034] 12 inner surface; 42 outer wall

[0035] 14 outer surface; 44 front end

[0036] 16 hole; M central axis

[0037] 20 gasket

[0038] 22 outer wall

[0039] 24 inner wall

Claims

1. A panel assembly for a vehicle comprising a composite laminated panel (10) having an inner panel (1), an outer panel (3) adjacent to the inner panel (1), and a thermoplastic intermediate panel (2) bonding together the inner and outer panels (1, 3), characterized in that, The through hole (16) extends between the outer surface (14) of the outer panel (3) and the inner surface (12) of the inner panel (1) on the laminated panel (10); a gasket (20) provides a seal between the through hole (16) and a sensor (40) positioned within the through hole (16), the gasket surrounding the sensor (40) in a manner to secure the sensor (40) to the laminated panel (10).

2. The panel assembly of claim 1, wherein, A housing (30) is directly supported in the laminated panel (10) by the gasket (20) and at least partially surrounds the sensor (40).

3. The panel assembly according to any of the preceding claims, wherein, The gasket (20) is made of a flexible material.

4. The panel assembly of claims 2-3, wherein, The housing (30) is aligned at a front end (44) with the outer surface (14) of the outer panel (3).

5. The panel assembly of claims 2-4, wherein, The housing (30) is made of a rigid material.

6. The panel assembly of claim 5, wherein, A guide structure, in particular a thread, is provided within an inner wall (34) of the housing (30), an outer wall (44) of the sensor (40) directly engages at the guide structure in a leak-proof manner.

7. The panel assembly of claims 2-6, wherein, A rear portion of the housing (30) extends inwardly from the inner surface (12) and is supported by a gasket (20) across a distance at a front portion (35), the distance being equal to a thickness of the laminated panel (10) corresponding to the through hole (16).

8. The panel assembly according to any of the preceding claims, wherein, The housing (30) is coaxially aligned with the sensor (40).

9. The panel assembly according to any of the preceding claims, wherein, The gasket (20) comprises polyurethane.

10. A panel assembly according to any preceding claim, wherein, The inner panel (1) and the outer panel (3) are made of a glass material.

11. A panel assembly according to any preceding claim, wherein, The intermediate panel (2) is made of a PVB material and is directly adjacent to the inner and outer panels (1, 3).

12. A panel assembly according to any preceding claim, wherein, The through hole (16) is provided near a central axis (M) of the laminated panel (10) and adjacent to the upper edge (11).

13. The panel assembly according to any one of the preceding claims, wherein, The sensor (40) comprises a video camera.

14. A manufacturing method for manufacturing a panel assembly according to any of the preceding claims, comprising the steps of: The laminated panel (10) is obtained by arranging the inner panel (1), the intermediate panel (2) and the outer panel (3) directly adjacent on top of each other, the laminated panel (10) is longitudinally cut to provide the hole (16) and comprises the step of providing the annular gasket (20) within the hole (16).

15. The manufacturing method of claim 14, comprising the steps of: The housing (30) is mounted from an outer wall (42) to an inner wall (22) of the gasket (20).

Images