Composite Pane Waviness Compensation
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Solution Overview
Problem
Composite panes, particularly windshields, suffer from optical distortions due to production-related waviness in flat glass and thermoplastic films, leading to uneven optical refractive power and distorted vision when viewed at different angles.
Innovation Solution
The composite pane design features flat glass panes with production-related waviness oriented at an angle relative to the extrusion direction of the thermoplastic film, which compensates for the waviness and reduces local optical refractive power differences, using thermoplastic films with specific waviness patterns to improve optical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the glass strip is pulled out faster to reduce pane thickness, then the pane thickness is reduced, but the float lines become more pronounced causing greater optical distortion
Solution Approach 1:
The patent applies asymmetry by deliberately orienting the waviness patterns of the glass pane and thermoplastic film at different angles relative to each other. The glass pane waviness is oriented at a first angle while the thermoplastic film waviness is oriented at a second angle that differs by more than 0 degrees but less than or equal to 45 degrees. This asymmetric angular arrangement prevents the waviness patterns from aligning and reinforcing each other, thereby reducing optical distortion while maintaining thin pane thickness.
Solution Approach 2:
The patent changes the angular orientation parameter of the waviness patterns as a key design variable. By controlling the angle between the waviness directions of the glass pane and thermoplastic film to be within 0-45 degrees, the patent optimizes the optical properties. This parameter change transforms the harmful effect of waviness into a controllable design feature that reduces overall optical distortion.
2Ease of manufacture
If the waviness of flat glass and thermoplastic film are aligned perpendicular to each other, then production is simplified, but optical distortion is maximized due to overlapping float lines and draw lines
Solution Approach 1:
Instead of aligning waviness patterns at 0 degrees (parallel) or 90 degrees (perpendicular), the patent introduces asymmetric angular orientation where the glass pane waviness and thermoplastic film waviness are oriented at different angles within a specific range (0-45 degrees difference). This asymmetric arrangement prevents the formation of pronounced float lines and draw lines that cause optical distortion, while still maintaining relatively simple production processes.
Solution Approach 2:
The patent applies local quality by allowing different regions of the composite pane to have different waviness orientations. The glass pane has its own waviness pattern oriented at one angle, while the thermoplastic film has a different waviness pattern oriented at another angle. This localized differentiation of waviness characteristics optimizes optical properties without requiring complete uniformity across the entire structure.
3Reliability
If thermoplastic film is embossed with intentional roughness to promote deaeration, then deaeration is improved, but the distinction between intentional roughness and unwanted waviness becomes difficult
Solution Approach 1:
The patent applies local quality by creating distinct surface patterns with different characteristics in different layers. The thermoplastic film receives intentional embossing with a specific waviness pattern, while the glass pane has its own production-related waviness pattern. By controlling the angular orientation difference between these patterns (0-45 degrees), the patent ensures that intentional roughness for deaeration can be distinguished from unwanted waviness, as they exhibit different spatial frequencies and orientations.
Solution Approach 2:
The patent changes the spatial frequency and angular orientation parameters to differentiate between intentional embossing patterns and unwanted waviness. The intentional embossing has a specific wavelength and amplitude optimized for deaeration, while the unwanted waviness from production has different characteristics. By controlling the angular relationship between these patterns, the patent makes them distinguishable and ensures that the deaeration function is not compromised by confusing surface patterns.
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 configuration significantly reduces optical distortions and improves vision clarity by minimizing differences in local optical refractive power, particularly effective with very thin panes, enhancing both optical performance and stability.
Implementation Method 1
The elongated elevations of the at least one pane and the elongated elevations of the thermoplastic film are oriented at an angle different from 90° relative to one another, thereby compensating for the waviness and reducing differences in local optical refractive power
Data Source
AI summary
A composite pane includes a first pane, a second pane, and a thermoplastic film arranged between the two panes, wherein at least one pane is in the form of a flat glass and at least one pane surface has a plurality of elongated elevations and elongated depressions that extend along a first pane direction and are alternatingly arranged in a second pane direction perpendicular to the first pane direction, the thermoplastic film is produced by extrusion and at least one film surface has a plurality of elongated elevations and elongated depressions that extend along a first film direction and are alternatingly arranged in a second film direction perpendicular to the first film direction, wherein the elongated elevations of the at least one pane are arranged at an angle different from 90° relative to the elongated elevations of the thermoplastic film.