Composite Pane Busbar Integration for Defect-Free Deaeration
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Solution Overview
Problem
Existing composite panes with functional films and busbars face challenges in deaeration, leading to air inclusions and defects due to the complexity of integrating busbars in the edge region, especially when using materials with low adhesion to glass, such as polyethylene terephthalate (PET) and other polymers.
Innovation Solution
A composite pane design where the busbar is integrated between the peripheral edge of the functional film and the composite pane edge, maintaining a distance of 5 mm to 50 mm, ensuring sufficient space for air escape and uniform filling by the thermoplastic bonding film during lamination, thereby preventing air inclusions and defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a busbar is integrated close to the functional film in the composite pane, then the electrical contacting is more compact and device complexity is reduced, but air inclusions and defects occur due to incomplete deaeration
Solution Approach 1:
The busbar is pre-positioned at a specific distance (5-50 mm) from the functional film before lamination. This preliminary positioning creates sufficient space for air to escape during the subsequent lamination process, preventing air inclusions while maintaining compact integration. The distance is optimized in advance to balance deaeration requirements with integration compactness.
2Reliability
If the functional film peripheral edge is set-back from the composite pane peripheral edge, then adhesion problems are avoided for low-adhesion materials, but the space for busbar integration and air escape is reduced
Solution Approach 1:
The functional film is positioned with its peripheral edge set back from the composite pane peripheral edge by a specific distance. This creates a local quality difference: the edge region has sufficient space for busbar integration and air escape, while the functional film area maintains optimal adhesion characteristics. The setback distance is optimized to provide both adhesion reliability and integration space.
3Strength
If thermoplastic bonding film is used to encase the functional film, then bonding strength is improved, but air inclusions occur due to trapped air during lamination
Solution Approach 1:
The functional film is pre-positioned with its peripheral edge set back from the composite pane edge, creating a deaeration channel before lamination begins. This preliminary arrangement ensures that when the thermoplastic bonding film is applied and heated, air can escape through the edge region without being trapped between the bonding film and functional film, maintaining both bonding strength and deaeration quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enables defect-free deaeration and uniform lamination, improving the integration of functional films with busbars in composite panes, particularly suitable for automotive glazings like windshields, by ensuring the busbar distance allows for effective material flow and air removal.
Implementation Method 1
The outer pane (2) and the inner pane (6) are joined to one another via a thermoplastic intermediate layer (3)
Implementation Method 2
The busbar (5) makes electrically conductive contact with the electrically conductive layer (7)
Data Source
AI summary
A composite pane with functional film includes a peripheral edge of the composite pane, a peripheral edge of the functional film, a busbar, an outer pane with exterior-side and interior-side surfaces, an inner pane with exterior-side and interior-side surfaces, and a thermoplastic intermediate layer that joins the interior-side surface of the outer pane to the exterior-side surface of the inner pane. The functional film is encased in the thermoplastic intermediate layer, the peripheral edge of the functional film is set back in the direction of the surface center of the composite pane relative to the peripheral edge of the composite pane, and the busbar is arranged between the interior-side surface of the outer pane and the exterior-side surface of the inner pane and runs between the peripheral edge of the composite pane and the peripheral edge of the functional film in the edge region of the composite pane.