Embedded Wire Circuit Automotive Lamination Process
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Solution Overview
Problem
The high cost and labor-intensive process of manufacturing embedded wire circuits for automotive glazing, particularly for windshields with camera and heated wiper area defrosters, limit their widespread adoption due to higher power density requirements and the need for large, expensive CNC machines, resulting in higher production costs and limited throughput.
Innovation Solution
Producing multiple defroster circuits on a single interlayer sheet, allowing for the use of smaller, less expensive machines and reducing storage and labor costs, by cutting the interlayer to fit individual circuits and assembling them during the lamination process, which reduces capital investment and floor space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple defroster circuits are produced on a single interlayer sheet, then productivity increases and manufacturing cost decreases, but manufacturing precision and device complexity increase
Solution Approach 1:
The patent divides the manufacturing process into segments: multiple circuits are embedded simultaneously on a single interlayer sheet, then the interlayer is cut into individual pieces, and circuits are reassembled during lamination. This segmentation allows high-volume production on one sheet while maintaining precision through controlled cutting and assembly processes.
Solution Approach 2:
A single interlayer sheet serves multiple functions: it acts as the bonding layer between glass panes and simultaneously carries multiple embedded wire circuits that will be distributed to different windshield positions. This multi-functionality enables efficient resource utilization and streamlined manufacturing.
2Device complexity
If smaller machines are used to produce multiple circuits on a single interlayer sheet, then capital investment and floor space requirements decrease, but the ability to handle large interlayer sheets may be limited
Solution Approach 1:
Instead of requiring one large machine to handle entire windshield-sized interlayer sheets, the patent segments the interlayer into smaller manageable sheets that can be processed by smaller, more affordable machines. These smaller sheets are then assembled during the lamination process to create the final product.
3Reliability
If embedded wire circuits are used for camera and heated wiper area defrosters, then deicing performance improves, but manufacturing cost increases due to higher power density requirements
Solution Approach 1:
The patent combines multiple defroster circuits (camera area defroster and heated wiper area defroster) onto a single interlayer sheet during one embedding process. This merging approach allows simultaneous production of multiple high-performance circuits, distributing the manufacturing cost across multiple functional units rather than producing them separately.
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 approach lowers production costs, increases throughput, reduces storage needs, and allows the use of smaller machines, making embedded wire defrosters more economically viable and efficient, enabling faster deicing times for windshields with camera and heated wiper area defrosters.
Implementation Method 1
electrical heating circuits so as to maintain clear unobstructed vision by heating the glass to help keep it clear of ice, snow and fog
Implementation Method 2
two layers of annealed glass held together by a thin sheet of plastic interlayer
Data Source
AI summary
Laminated glazings with embedded wire circuits, have many uses. But, due to the higher cost of manufacture, they are not widely used. This invention provides a process to reduce the cost of production for embedded wire laminated glazing. Rather than embedding the wire one interlayer at a time, several circuits are produced on the same sheet, cut out and then inserted into the interlayer of each separate laminate during assembly, reducing the direct labor and capital investment required.