Composite Pane Inlay Structure for Clear Heated Sensor Windows
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing composite panes for vehicle windshields face issues such as glass breakage during bending, optical distortions in sensor windows, and the need for separate application of masking prints and heating elements, which complicates production and affects optical quality.
Innovation Solution
A composite pane design featuring a functional inlay element with a carrier layer and electrically conductive elements, such as heating wires, antennas, and sensors, integrated between two panes via a thermoplastic intermediate layer, allowing for simultaneous incorporation of multiple functions and reducing the need for separate application steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a masking print is applied on the pane by screen printing before bending, then the sensors are obscured and UV protection is provided, but optical distortions occur in sensor windows and glass breakage can happen during the bending process
Solution Approach 1:
The masking function is segmented from the bending process. Instead of applying masking print before bending, the patent applies the masking print after the panes are joined, separating the masking operation from the thermal bending process that causes optical distortions
Solution Approach 2:
The panes are joined together in advance through lamination before the masking print is applied. This preliminary joining action allows the subsequent masking application to occur at lower temperatures, preventing the thermal distortion issues that occur when masking is applied before bending
2Reliability
If heating wires are laminated into the sensor window region, then the sensor windows can be kept free of ice or fog, but the optical quality of the sensor windows deteriorates
Solution Approach 1:
A transparent intermediate layer is introduced between the heating wires and the sensor window. This intermediate layer allows the heating function to be maintained while preventing direct contact between the heating wires and the optical path, thereby preserving optical quality
Solution Approach 2:
A transparent thin film or coating is applied to the inner pane in the sensor window region. This thin film serves as a carrier for the heating elements while maintaining optical transparency, allowing heat transfer to prevent ice and fog without compromising the optical quality
3Manufacturing precision
If multiple functional elements are applied or incorporated individually, then each element can be precisely installed, but the production process becomes complex and time-consuming
Solution Approach 1:
Multiple functional elements (sensors, heating elements, antennas) are merged into a single integrated assembly mounted on the inner pane. This combining approach allows all elements to be installed together in one operation, maintaining precise positioning while significantly improving production efficiency
Solution Approach 2:
A single mounting structure on the inner pane serves multiple functions by holding different types of functional elements (sensors, heating elements, antennas) simultaneously. This multi-functional approach simplifies the production process while maintaining the precision needed for each element's operation
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 reduces the risk of glass breakage during bending, improves optical quality of sensor windows, and simplifies the production process by integrating multiple functional elements in a single step, enhancing overall efficiency and performance.
Implementation Method 1
at least a first pane (2) and a second pane (3) that are joined to one another via at least one thermoplastic intermediate layer (4)
Data Source
AI summary
A composite pane includes a first pane and a second pane joined to one another via at least one thermoplastic intermediate layer and a functional inlay element arranged between the first pane and the second pane. The functional inlay element includes a carrier layer and at least one electrically conductive element.