Composite Pane Recess for Post-Lamination Display Insertion
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Solution Overview
Problem
Modern vehicle windshields with integrated LED-based displays face issues due to high temperature and pressure during lamination, leading to poor optical appearance and high reject rates, as existing methods expose the displays to these conditions, causing deterioration.
Innovation Solution
A composite pane design featuring an outer and inner pane connected via a thermoplastic intermediate layer with a recess to accommodate an electrical consumer, allowing it to be inserted post-lamination, thus avoiding exposure to high temperatures and pressures, and using a placeholder during lamination to create a recess for the consumer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electrical consumer is integrated between the two panes of glass during lamination, then the composite pane structure is achieved, but the appearance of the electrical consumer deteriorates due to exposure to high temperatures and pressure
Solution Approach 1:
A recess is created in the thermoplastic intermediate layer before the lamination process, and a placeholder is positioned in this recess. The electrical consumer is then inserted into the recess after lamination, avoiding exposure to high temperatures and pressure. This preliminary preparation of the recess and placeholder enables subsequent insertion without compromising the electrical consumer's appearance.
Solution Approach 2:
The manufacturing process is divided into separate stages: first, the panes and intermediate layer are laminated without the electrical consumer; second, the electrical consumer is inserted into the pre-prepared recess after lamination. This segmentation allows the electrical consumer to be integrated into the composite pane structure while avoiding direct exposure to harmful lamination conditions.
2Manufacturing precision
If the electrical consumer is inserted after lamination, then the appearance quality is maintained, but additional manufacturing steps are required
Solution Approach 1:
The recess is pre-formed in the thermoplastic intermediate layer before lamination, and a placeholder is positioned in advance. This preliminary action simplifies the post-lamination process, as the electrical consumer can be directly inserted into the ready-made recess without requiring complex additional manufacturing steps.
Solution Approach 2:
A placeholder is used as an intermediary element during the lamination process. The placeholder occupies the recess during lamination, protecting the space where the electrical consumer will later be inserted. This intermediary approach simplifies the overall process by enabling easy post-lamination insertion while maintaining structural integrity during manufacturing.
3Ease of operation
If the receiving opening is made larger to facilitate insertion, then ease of installation improves, but the structural integrity of the intermediate layer may be compromised
Solution Approach 1:
The recess is pre-formed with the exact dimensions needed for the electrical consumer, and the placeholder is positioned in advance. This allows for precise sizing of the receiving opening that is just large enough to accommodate the electrical consumer while minimizing the opening size to preserve the structural integrity of the thermoplastic intermediate layer.
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
Maintains the visual clarity and effectiveness of the electrical consumer, such as displays, by preventing damage from lamination processes, resulting in improved appearance and reduced reject rates, with the consumer remaining functional and clearly visible.
Implementation Method 1
an outer pane (3) and an inner pane (5) which are connected to one another via a thermoplastic intermediate layer (4)
Implementation Method 2
the high temperatures and pressure required during lamination
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a laminated pane (1) comprising an electric consumer (9), an outer sheet (3) and an inner sheet (5) which are bonded to each other by means of a thermoplastic intermediate layer (4), wherein • the thermoplastic intermediate layer (4) has a cutout (6) which includes an insertion hole (8), • the insertion hole (8) is sized such that the electric consumer (9) can be inserted into the cutout (6) through the insertion hole (8) and the electric consumer (9) is placed in the cutout (6).