Composite Pane LED Embedding via Local Film Heating
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Solution Overview
Problem
Existing methods for producing composite vehicle panes with embedded electronic components, such as LEDs, face issues with stress development due to thickness mismatch and mechanical damage during the calendering process, leading to potential glass breakage and increased production costs.
Innovation Solution
A method involving a plastic film between two panes, where the LED is inserted into a locally heated section of the film, allowing it to displace the film's volume and create a recess, thus avoiding stress and mechanical damage, and enabling the use of thicker, more economical LEDs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If electronic components are arranged adjacent the thermoplastic intermediate layer during calendering, then the intermediate layer compensates the thickness of the components, but thicker electronic components cause glass breakage due to stress development
Solution Approach 1:
The patent divides the heating process into two distinct stages: local heating before LED insertion and global heating during lamination. This segmentation allows the plastic film to be softened locally to accommodate thicker LEDs without compromising the overall structural integrity of the panes during the global lamination process.
Solution Approach 2:
The patent performs preliminary local heating of the plastic film at the LED insertion position before the actual LED placement. This preliminary action creates a localized softened region that can accommodate thicker LED components without causing stress, while the rest of the film remains intact for subsequent global lamination.
2Ease of manufacture
If LEDs are embedded during calendering via a pair of rollers, then the LEDs are integrated into the composite pane, but the LEDs and their electrical connections are damaged due to mechanical forces
Solution Approach 1:
The patent performs preliminary local heating and LED insertion before the global lamination process. This preliminary action allows LEDs to be carefully positioned and embedded in a controlled manner, protecting their electrical connections from the high mechanical forces that would occur during calendering with rollers.
Solution Approach 2:
The patent extracts the LED embedding step from the global calendering process and performs it as a separate, preliminary operation. This extraction allows the LED insertion to be performed under controlled local heating conditions, avoiding the damaging mechanical forces of the main lamination process.
3Stability of the object's composition
If the entire plastic film is heated during lamination, then the panes are joined together, but air pockets form and bonding is compromised
Solution Approach 1:
The patent segments the heating process into local heating before LED insertion and global heating during lamination. The local heating is performed first to embed the LED, then the plastic film is heated globally during lamination to ensure proper bonding and eliminate air pockets, achieving both LED integration and secure pane bonding.
Solution Approach 2:
The patent performs preliminary local heating and LED insertion before the global lamination heating. This preliminary action allows the LED to be embedded in a localized softened region, and subsequent global heating ensures proper bonding without trapping air pockets, as the film is uniformly heated and pressed during lamination.
4Temperature
If the plastic film is locally heated exclusively in one section, then the LED can be introduced without heating the entire film, but precise temperature control is required
Solution Approach 1:
The patent applies local quality by heating only the specific section of the plastic film where the LED will be inserted, rather than heating the entire film. This localized heating allows the LED to be embedded in a softened region while the rest of the film remains at ambient temperature, simplifying temperature control and preventing unwanted effects in other areas.
Solution Approach 2:
The patent segments the heating process spatially, applying heat only to the local region where LED insertion is required. This spatial segmentation allows independent temperature control of the insertion zone, reducing the complexity of overall temperature management and enabling precise local heating without affecting the entire film.
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 method prevents stress in the panes, protects sensitive electrical connections, and allows for precise positioning of LEDs, reducing production rejects and costs while avoiding air pockets and ensuring safe embedding of LEDs during the lamination process.
Implementation Method 1
heating the plastic film at least in the region of the LED into a fluid state with the heating source
Implementation Method 2
heating the plastic film at least in the region of the LED into a fluid state
Data Source
AI summary
A method for producing a composite pane for a motor vehicle includes heating the plastic film at least in the region of the LED into a fluid state by a heating source positioned on an outer surface of the first pane or the second pane or arranged at a distance from the outer surface of the first pane or the second pane, and introducing the LED into the plastic film into the fluid state with displacement of a predefined volume of the plastic film. After introducing the LED into the plastic film, the method includes laminating the first pane and the second pane with the interposed plastic film.