Automotive glazing for improved image clarity

Abstract

To provide an automotive glazing assembly designed to enhance the functionality of vehicular sensor devices, particularly cameras.SOLUTION: An automotive glazing assembly includes an outer glass layer with a uniform thickness, an inner glass layer with a uniform thickness, and a polymer layer situated between the two glass layers, bonding them together. A unique feature of this assembly is a localized area where the inner glass and polymer layers are removed and replaced with a wedge patch. This patch consists of a wedge-shaped polymer layer with a non-uniform thickness that increases in one direction, and a flat glass element attached to it. The wedge patch is specifically designed to reduce total internal reflection and double imaging, thereby improving the optical clarity for cameras positioned behind the windshield. This technological innovation deals with necessity of clear sensor visibility without damaging structural integrity and design of the automotive glazing.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] This disclosure relates generally to automotive glazing technology. More specifically, the present invention relates to structural and material reinforcement of windshields to improve the functionality of vehicle sensors. [Background technology]

[0002] Modern vehicles are increasingly equipped with advanced driver-assistance systems (ADAS) that rely on sensors, including cameras, to monitor the vehicle's surroundings. These cameras are often located behind the windshield and require a clear, unobstructed view to function optimally. However, a standard automotive windshield can present certain optical challenges that degrade the quality of the images captured by these cameras.

[0003] One such challenge is double imaging, or ghosting, where a single light source appears as two or more images. This effect is caused by multiple reflections within the windshield's glass layers, resulting in total internal reflection. Double imaging can significantly impair the camera's ability to accurately analyze visual data that is critical for the safe operation of ADAS features such as lane departure warning, adaptive cruise control, and emergency braking systems.

[0004] Another problem arises from the curvature and thickness of conventional windshields, which can cause distortion and refraction of light as it passes through the glass. This distortion can alter the perceived position of objects and reduce the camera's ability to accurately measure distance and relative velocity, potentially compromising the effectiveness of ADAS.

[0005] The automotive industry has attempted to address these issues through various means. One approach has been to apply special coatings or treatments to the windshield glass to reduce reflections and refractions. Another strategy involves using a flat glass panel in front of the camera, which can minimize distortion but may be incompatible with the overall design and aerodynamics of the vehicle. [Brief explanation of the drawings]

[0006] To easily identify the description of any particular element or function, the most significant digit(s) of a reference number refers to the figure number in which that element is first introduced.

[0007] [Figure 1] FIG. 1 illustrates an example of an automotive glazing assembly for improving image clarity for one or more sensor devices, according to an example.

[0008] [Figure 2] FIG. 1 illustrates a cross section of an automotive glazing assembly for improving image clarity for one or more sensor devices, according to an example.

[0009] [Figure 3] 1 is a flow chart illustrating a method of manufacturing an automotive glazing assembly for improving image clarity for one or more sensor devices, according to an example. DETAILED DESCRIPTION OF THE INVENTION

[0010] According to some examples, an automotive glazing assembly is described herein for reducing optical distortions affecting vehicle sensor devices, particularly cameras, due to the characteristics of the windshield glass. Conventional automotive glazing can cause problems such as double images or ghosting, which can significantly impair the functionality of cameras used in advanced driver assistance systems (ADAS). These problems can arise from the inherent characteristics of standard windshield glass, including its curvature, thickness, and the potential for total internal reflection.

[0011] To address at least these challenges, some examples introduce automotive glazing assemblies that incorporate a wedge patch within a localized region of the windshield. The wedge patch is designed to reduce total internal reflection and improve optical clarity for a camera positioned behind the windshield. In some examples, the wedge patch comprises a wedge-shaped polymer layer having a non-uniform thickness that increases in one direction bonded to a flat glass element. In some examples, the polymer layer is composed of materials such as polyvinyl butyral (PVB), ionomer, or thermoplastic polyurethane (TPU), which are selected for their optical properties and compatibility with the rest of the glazing assembly.

[0012] According to some examples, the design of the wedge patch, including its dimensions and tilt angle, is adjusted based on the curvature and thickness of the windshield to address the specific optical requirements of a sensor, such as a camera.

[0013] According to some examples, an automotive glazing assembly includes a first (i.e., outer) glass layer and a second (i.e., inner) glass layer, each layer exhibiting a consistent, uniform thickness and joined by an equal, uniform polymer layer. The wedge patch is incorporated into a specifically defined localized area where the standard inner glass and polymer layer have been removed. The wedge patch includes a polymer layer that increases in thickness along one axis to form a wedge shape. As described above, the wedge-shaped polymer layer may be formed from one or more of polyvinyl butyral (PVB), ionomer, and thermoplastic polyurethane (TPU), selected for their optical properties and compatibility with the glazing assembly. In some examples, the wedge patch further includes a flat glass element secured to the wedge-shaped polymer layer.

[0014] The dimensions of the wedge patch may match the field of view of the sensor device to improve clarity over the entire operating range of the sensor. Additionally, in some examples, the wedge patch does not include a metallic coating that may interfere with the vehicle antenna's signal transmission.

[0015] 1 is a diagram 100 illustrating an example of an automotive glazing assembly 102 for improving image clarity of one or more sensor devices, according to some examples. The automotive glazing assembly 102, which may be a front, rear, or side window of a vehicle, includes a wedge patch 104 attached to a localized area 106.

[0016] The automotive glazing assembly 102 is comprised of a first glass layer and a second glass layer, each of uniform thickness to ensure optical clarity and structural stability. Between these glass layers is a polymer layer that bonds them together and maintains a uniform thickness throughout the assembly. This polymer layer not only acts as an adhesive, but also contributes to the safety and acoustic properties of the glazing assembly.

[0017] According to some examples described herein, an automotive glazing assembly 102 includes a wedge patch 104 strategically applied to a localized region 106 of the assembly. The localized region 106 may be located directly in front of one or more sensor devices, such as cameras, positioned behind the automotive glazing assembly 102. The sensor devices may be, for example, part of the vehicle's advanced driver assistance systems (ADAS), which require a clear, undistorted view through the glazing to function properly.

[0018] The wedge patch 104 may comprise a wedge-shaped polymer layer having a non-uniform thickness that increases in one direction along an axis. According to particular examples, the angle and thickness gradient of the wedge-shaped polymer layer may be adjusted to reduce or eliminate optical distortions, such as double images or ghosting, that may occur due to total internal reflection within the glazing assembly 102. The wedge patch 104 redirects light in a manner that minimizes these distortions, thereby improving the quality of the image captured by the sensor device.

[0019] According to some examples, the wedge patch 104 includes a glass element attached or otherwise bonded to a wedge-shaped polymer layer. The glass element may be flat or may cooperate with the wedge-shaped polymer layer to provide the necessary optical correction. The materials selected for the wedge-shaped polymer layer, such as polyvinyl butyral (PVB), ionomer, or thermoplastic polyurethane (TPU), are chosen for their optical properties, durability, and compatibility with the rest of the glazing assembly.

[0020] 2 is a diagram 200 illustrating a cross section of an automotive glazing assembly 202 for improving image clarity of one or more sensor devices, according to some examples. The automotive glazing assembly 202 may be incorporated into a vehicle as a front window, a rear window, or a side window.

[0021] According to some examples, automotive glazing assembly 202 includes several layers that contribute to its structural and optical properties. A first glass layer 204 is the exterior surface of the glazing assembly that faces the surrounding environment. A second glass layer 206 is positioned opposite first layer 204. This second layer 206 is the surface that faces the interior of the vehicle.

[0022] Between the first glass layer 204 and the second glass layer 206 are one or more polymer layers 208. These polymer layers 208 may bond the first and second glass layers 204, 206 together to form a laminate structure. The polymer layers 208 may be of uniform thickness.

[0023] According to some examples, automotive glazing assembly 202 may include wedge patches 210 disposed in localized areas to address specific optical requirements of one or more sensor devices associated with the vehicle. Wedge patches 210 include flat glass elements 212 and wedge-shaped polymer layers 214.

[0024] According to some examples, the wedge-shaped polymer layer 214 has a non-uniform thickness that increases in one direction, thereby minimizing total internal reflection and improving image clarity of the one or more sensor devices. The wedge-shaped polymer layer 214 may include one or more of polyvinyl butyral (PVB), an ionomer, and a thermoplastic polyurethane (TPU).

[0025] FIG. 3 is a flow diagram illustrating a method 300 of manufacturing an automotive glazing assembly for improving image clarity of one or more sensor devices, according to some examples.

[0026] In step 302, the method begins by providing a first glass layer having a first uniform thickness and a second glass layer having a second uniform thickness. The uniform thickness of each layer ensures consistent optical performance across the entire surface of the glazing assembly.

[0027] In step 304, one or more polymer layers are disposed between the first and second glass layers. For example, according to some examples, one or more polymer layers are applied to either the first or second glass layers prior to assembly of the automotive glazing. This third, uniformly thick polymer layer can serve as a bonding medium to bond the outer and inner glass layers into a single laminate structure. The polymer layer can be applied first onto the first glass layer, followed by aligning and bonding the second glass layer thereon, or vice versa. The order can depend on manufacturing process or equipment priorities. The polymer layer is made of a material selected for its excellent adhesive properties and light transmission, such as polyvinyl butyral (PVB), ionomer, or thermoplastic polyurethane (TPU).

[0028] In step 306, at least one sensor device is positioned adjacent to the automotive glazing assembly. The sensor device(s) may include cameras or other types of sensors used in advanced driver assistance systems (ADAS). The placement of the sensor device is carefully determined to ensure an unobstructed view through the glazing assembly. According to some examples, placement of the one or more sensor devices may occur after assembly of the automotive glazing.

[0029] According to some examples, the sensor device or devices may not be physically fixed to the glazing assembly itself, but instead may be positioned adjacent to or in close proximity to the fully assembled glazing assembly.

[0030] In step 308, portions of the second glass layer (i.e., the inner glass layer) and the polymer layer are removed in a localized area in front of at least one sensor device. This step involves precision cutting techniques to create recesses in the glazing assembly without damaging the surrounding structure. These portions are removed to accommodate the subsequent insertion of wedge patches that provide the desired optical correction for the sensor device.

[0031] In step 310, a wedge patch is bonded within a localized region to either the inner surface of the first glass layer (if all polymer layers are removed from the localized region) or to the inner surface of one of the one or more polymer layers. The wedge patch may comprise a wedge-shaped polymer layer having a non-uniform thickness that increases in one direction. This thickness gradient is specifically designed to correct optical distortions, such as double images or ghosting, that can affect the clarity of the sensor device's image. The wedge patch also includes a glass element attached to the wedge-shaped polymer layer. The glass element is flat and matches the optical properties of the rest of the glazing assembly. Bonding of the wedge patch is achieved using an optically compatible adhesive that ensures secure and seamless integration with the existing glass and polymer layers.

[0032] While the described flow charts may depict steps as a sequential process, many of the steps may be performed in parallel or simultaneously. Additionally, the order of steps may be rearranged. A process terminates when the step is completed. A process may correspond to a method, a procedure, an algorithm, etc. The steps of a method may be performed in whole or in part, may be performed in conjunction with some or all steps of other methods, and may be performed by any number of various systems, such as those described herein, or any portion thereof, such as a processor included in any of the systems.

[0033] example

[0034] Thus, some embodiments may include one or more of the following examples.

[0035] Example 1. An automotive glazing assembly comprising: a first glass layer; a second glass layer; a polymer layer disposed between the first glass layer and the second glass layer and bonding the first glass layer to the second glass layer; at least one sensor device disposed adjacent to the automotive glazing assembly; a localized region within the field of view of the at least one sensor device that is free of the second glass layer and the polymer layer; and a wedge patch disposed within the localized region, the wedge patch comprising a wedge-shaped polymer layer having a non-uniform thickness and a glass element attached to the wedge-shaped polymer layer.

[0036] Example 2. The automotive glazing assembly of Example 1, wherein the first glass layer has a first uniform thickness, the second glass layer has a second uniform thickness, and the polymer layer has a third uniform thickness.

[0037] Example 3. An automotive glazing assembly as described in Example 1, wherein the polymer layer comprises a plurality of polymer layers.

[0038] Example 4. The automotive glazing assembly of Example 1, wherein the at least one sensor device includes a camera.

[0039] Example 5. An automotive glazing assembly as described in Example 1, wherein the wedge patch reduces total internal reflection within a localized region in front of at least one sensor device in the automotive glazing assembly.

[0040] Example 6. An automotive glazing assembly as described in Example 1, wherein the wedge-shaped polymer layer comprises a material selected from the group consisting of polyvinyl butyral (PVB), ionomer, and thermoplastic polyurethane (TPU).

[0041] Example 7. An automotive glazing assembly as described in Example 1, wherein the automotive glazing assembly has a curvature and a thickness, and the wedge-shaped polymer layer has a tilt angle based on the curvature and thickness of the automotive glazing assembly.

[0042] Example 8. The automotive glazing assembly of Example 1, wherein the automotive glazing assembly comprises a curvature and a thickness, and the glass element comprises a flat glass element.

[0043] Example 9. An automotive glazing assembly as described in Example 1, wherein the localized area is defined by a cutout in the second glass layer and the wedge patch is inserted into the cutout.

[0044] Example 10. An automotive glazing assembly as described in Example 1, wherein the wedge patch is bonded to the polymer layer by an optically compatible adhesive.

[0045] Example 11. An automotive glazing assembly as described in Example 1, wherein the dimensions of the wedge patch are based on the field of view of at least one sensor device.

[0046] Example 12. An automotive glazing assembly as described in Example 1, wherein the wedge patch includes provision for at least one antenna, and the wedge-shaped polymer layer and flat glass element are free of a metal coating in the vicinity of the at least one antenna.

[0047] Example 13. An automotive front window assembly comprising: a first glass layer; a second glass layer; a polymer layer disposed between the first glass layer and the second glass layer and bonding the first glass layer to the second glass layer; at least one sensor device disposed adjacent to the automotive front window assembly; a localized region in front of the at least one sensor device where the second glass layer and the polymer layer have been removed; and a wedge patch disposed within the localized region, the wedge patch comprising a wedge-shaped polymer layer having a non-uniform thickness that increases in one direction; and a glass element attached to the wedge-shaped polymer layer.

[0048] Example 14. The automotive front window assembly of Example 13, wherein the first glass layer has a first uniform thickness, the second glass layer has a second uniform thickness, and the polymer layer has a third uniform thickness.

[0049] Example 15. The automotive front window assembly of Example 13, wherein the polymer layer comprises a plurality of polymer layers.

[0050] Example 16. The automotive front window assembly of example 13, wherein the at least one sensor device includes a camera.

[0051] Example 17. The automotive windshield assembly of Example 13, wherein the wedge patch reduces total internal reflection within a localized region in front of at least one sensor device in the automotive windshield assembly.

[0052] Example 18. An automotive front window assembly according to Example 13, wherein the wedge-shaped polymer layer comprises a material selected from the group consisting of polyvinyl butyral (PVB), ionomer, and thermoplastic polyurethane (TPU).

[0053] Example 19. The automotive front window assembly of Example 13, wherein the automotive front window assembly has a curvature and a thickness, and the wedge-shaped polymer layer has a tilt angle based on the curvature and thickness of the automotive front window assembly.

[0054] Example 20. A method of manufacturing an automotive glazing assembly, comprising: preparing a first glass layer having a first uniform thickness; preparing a second glass layer having a second uniform thickness; disposing a polymer layer having a third uniform thickness between the first glass layer and the second glass layer to bond the first glass layer to the second glass layer; disposing at least one sensor device behind the automotive glazing assembly; removing a portion of the second glass layer and the polymer layer in a localized region in front of the at least one sensor device; and bonding a wedge patch in the localized region, wherein the wedge patch comprises a wedge-shaped polymer layer having a non-uniform thickness that increases in one direction; and a glass element attached to the wedge-shaped polymer layer.

[0055] While the above is a detailed description of some examples of the inventive subject matter, various alternatives, modifications, and equivalents may be used, and therefore the above description should not be construed as limiting the scope of the inventive subject matter, which is defined by the appended claims.

Claims

1. 1. An automotive glazing assembly comprising: a first glass layer; a second glass layer; and a polymer layer disposed between the first glass layer and the second glass layer, bonding the first glass layer to the second glass layer; at least one sensor device positioned adjacent to the automotive glazing assembly; a localized area within a field of view of the at least one sensor device that is free of the second glass layer and the polymer layer; a wedge patch disposed within the local region; Equipped with The wedge patch is a wedge-shaped polymer layer having a non-uniform thickness; a glass element attached to the wedge-shaped polymer layer; An automotive glazing assembly comprising:

2. 10. The automotive glazing assembly of claim 1, wherein the first glass layer comprises a first uniform thickness, the second glass layer comprises a second uniform thickness, and the polymer layer comprises a third uniform thickness.

3. The automotive glazing assembly of claim 1 , wherein the polymer layer comprises multiple polymer layers.

4. The automotive glazing assembly of claim 1 , wherein the at least one sensor device includes a camera.

5. The automotive glazing assembly of claim 1 , wherein the wedge patch reduces total internal reflection within the localized area in front of the at least one sensor device within the automotive glazing assembly.

6. 10. The automotive glazing assembly of claim 1, wherein the wedge-shaped polymer layer is comprised of a material selected from the group consisting of polyvinyl butyral (PVB), ionomer, and thermoplastic polyurethane (TPU).

7. 10. The automotive glazing assembly of claim 1, wherein the automotive glazing assembly comprises a curvature and a thickness, and the wedge-shaped polymer layer comprises a tilt angle based on the curvature and thickness of the automotive glazing assembly.

8. 10. The automotive glazing assembly of claim 1, wherein the automotive glazing assembly comprises a curvature and a thickness, and the glass element comprises a flat glass element.

9. The automotive glazing assembly of claim 1 , wherein the localized area is defined by a cutout in the second glass layer, and the wedge patch is inserted into the cutout.

10. The automotive glazing assembly of claim 1 , wherein the wedge patch is bonded to the polymer layer by an optically compatible adhesive.

11. The automotive glazing assembly of claim 1 , wherein the dimensions of the wedge patch are based on a field of view of the at least one sensor device.

12. 10. The automotive glazing assembly of claim 1, wherein the wedge patch includes provision for at least one antenna, and the wedge-shaped polymer layer and the flat glass element are free of metal coatings in the vicinity of the at least one antenna.

13. 1. A front window assembly for a motor vehicle, comprising: a first glass layer; a second glass layer; and a polymer layer disposed between the first glass layer and the second glass layer, bonding the first glass layer to the second glass layer; at least one sensor device positioned adjacent to the automotive front window assembly; a localized area on the front side of the at least one sensor device where the second glass layer and the polymer layer have been removed; a wedge patch disposed within the local region; Equipped with The wedge patch is a wedge-shaped polymer layer having a non-uniform thickness that increases in one direction; a glass element attached to the wedge-shaped polymer layer; A front window assembly for an automobile.

14. 14. The automotive front window assembly of claim 13, wherein the first glass layer has a first uniform thickness, the second glass layer has a second uniform thickness, and the polymer layer has a third uniform thickness.

15. 14. The automotive front window assembly of claim 13, wherein the polymer layer comprises a plurality of polymer layers.

16. 14. The automotive front window assembly of claim 13, wherein the at least one sensor device includes a camera.

17. 14. The automotive windshield assembly of claim 13, wherein the wedge patch reduces total internal reflection within the localized area in front of the at least one sensor device within the automotive windshield assembly.

18. 14. The automotive front window assembly of claim 13, wherein the wedge-shaped polymer layer is comprised of a material selected from the group consisting of polyvinyl butyral (PVB), ionomer, and thermoplastic polyurethane (TPU).

19. 14. The automotive windshield assembly of claim 13, wherein the automotive windshield assembly has a curvature and a thickness, and the wedge-shaped polymer layer has a tilt angle based on the curvature and thickness of the automotive windshield assembly.

20. 1. A method of manufacturing an automotive glazing assembly, comprising: providing a first glass layer having a first uniform thickness; providing a second glass layer having a second uniform thickness; disposing a third uniformly thick polymer layer between the first and second glass layers to bond the first glass layer to the second glass layer; positioning at least one sensor device behind the automotive glazing assembly; removing a portion of the second glass layer and the polymer layer in a localized area on a front side of the at least one sensor device; bonding a wedge patch within the localized region; Including, The wedge patch is a wedge-shaped polymer layer having a non-uniform thickness that increases in one direction; a glass element attached to the wedge-shaped polymer layer; A method comprising:

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