Composite Pane Lamination With Recessed Functional Element Positioning
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Solution Overview
Problem
Existing methods for manufacturing composite discs with functional elements face challenges in ensuring precise positioning and protection of the functional element during lamination, particularly due to air pocket formation and moisture exposure.
Innovation Solution
A method involving the sequential steps of joining thermoplastic interlayers to form a pre-composite, then partially removing one layer to create a recess, inserting a functional element, and laminating it between two disks, ensuring the functional element and recess dimensions match, and optionally using adhesive or thermoplastic layers for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the functional element is surrounded by an intermediate layer in a frame-like manner with a recess, then the functional element is protected from moisture and environmental influences, but air pockets may form during lamination between the intermediate layers
Solution Approach 1:
The recess is formed in the intermediate layer before the functional element is inserted. This preliminary preparation ensures that the recess is already precisely shaped and positioned, allowing the functional element to be inserted without creating air pockets during the subsequent lamination process. The recess acts as a pre-formed cavity that guides the functional element into place.
Solution Approach 2:
The intermediate layer with the recess acts as an intermediary structure between the functional element and the surrounding environment. The recess in the intermediate layer serves as a mediator that both protects the functional element from moisture while providing a controlled space that prevents air pocket formation during lamination.
2Reliability
If the functional element is surrounded by an intermediate layer in a frame-like manner, then the functional element is protected from moisture, but the manufacturing process becomes more complex
Solution Approach 1:
The intermediate layer is segmented by forming a recess in it, which divides the layer into a protective frame portion and a recessed cavity portion. This segmentation allows the functional element to be inserted into the recess while maintaining the protective function, simplifying the overall manufacturing process compared to creating a complete frame structure.
Solution Approach 2:
The recess is formed in the intermediate layer as a preliminary step before inserting the functional element. This preliminary action simplifies the subsequent assembly process by pre-preparing the receiving cavity, reducing the need for complex frame structures and multiple assembly steps.
3Manufacturing precision
If the functional element is inserted into a recess in the intermediate layer, then positioning is improved, but the intermediate layer must be precisely formed
Solution Approach 1:
The recess is formed in the intermediate layer as a preliminary step before inserting the functional element. This preliminary formation of the recess ensures precise positioning of the functional element while the recess itself is created using standard manufacturing techniques, balancing precision requirements with ease of manufacture.
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
Ensures precise positioning and protection of the functional element, preventing air pockets and moisture ingress, thereby enhancing the manufacturing process efficiency and quality of composite discs.
Implementation Method 1
Joining the first thermoplastic interlayer, the second thermoplastic interlayer, and the third thermoplastic interlayer to form a pre-composite
Implementation Method 2
Joining the first disk and the second disk via the stack of layers by lamination
Data Source
Figure 1~3
Figure 4~6
Figure 7~9
AI summary
A method for producing a composite pane (1), wherein at least a first thermoplastic intermediate layer (2), a second thermoplastic intermediate layer (3) and a third thermoplastic intermediate layer (4) are arranged in full surface contact one above the other, the first thermoplastic intermediate layer (2), the second thermoplastic intermediate layer (3) and the third thermoplastic intermediate layer (4) are connected to form a preliminary composite (5), and then material is removed from certain regions of the third thermoplastic intermediate layer (4) to form an aperture (6), a layered stack (7) is formed by a functional element (8) being introduced into the aperture (6) in the third thermoplastic intermediate layer (4), the layered stack (7) is arranged between a first pane (9) and a second pane (10), and the first pane (9) and the second pane (10) are laminated together via the layered stack (7). The functional element (8) has a thickness of ≥ 50 µm, and the third thermoplastic intermediate layer (4) has a thickness which corresponds substantially to the thickness of the functional element (8). The outer dimensions of the aperture (6) correspond substantially to the outer dimensions of the functional element (8).