Laminated Glass Corrugation Alignment for Optical Distortion Reduction
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Solution Overview
Problem
Conventional windshield manufacturing techniques result in small waviness profiles on sheet glass surfaces, leading to optical distortion in images captured through the windshield due to random corrugations, which cannot be completely eliminated by existing methods.
Innovation Solution
Aligning and bonding the fine corrugation profiles on the front and back surfaces of the windshield to ensure parallel incidence and exit angles of light beams, effectively reducing optical distortion by considering the corrugation profiles only on one surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sheet glass is manufactured using conventional float process, then production efficiency is maintained, but small waviness profiles and random corrugations are formed on the glass surfaces causing optical distortion
Solution Approach 1:
The patent applies preliminary action by pre-aligning the corrugation profiles of the first and second sheet glasses before bonding them together. The manufacturing method includes steps to measure the corrugation profiles, calculate alignment amounts, and adjust the positional relationship between the sheets so that their corrugation profiles substantially coincide. This preliminary alignment ensures that when light passes through both sheets, the optical distortions cancel each other out, eliminating the need for post-manufacturing optical correction while maintaining conventional production efficiency
Solution Approach 2:
The patent converts the harmful effect of random corrugations into a beneficial outcome by deliberately aligning identical corrugation patterns from two separate glass sheets. Instead of trying to eliminate the waviness profiles formed during conventional float glass manufacturing, the method uses the correlation between the two sheets' corrugations to achieve optical compensation. By making the corrugation profiles coincide, the combined optical path creates a net reduction in distortion, effectively transforming the manufacturing defect into an optical advantage
2Measurement precision
If image processing correction is applied to compensate for windshield distortion, then optical distortion effect is reduced, but positional shifts due to impact or vibration cause distortion to recur
Solution Approach 1:
The patent applies preliminary action by performing optical alignment during the windshield manufacturing process itself, rather than relying on post-installation image processing. The corrugation profiles of both glass sheets are measured and aligned before bonding, creating a physically stable optical configuration that is inherent to the windshield structure. This preliminary optical correction is built into the windshield's physical geometry, making it immune to later positional shifts or vibrations that would affect electronic image processing solutions
Solution Approach 2:
The patent replaces the mechanical/electronic image processing correction system with a physical-optical solution. Instead of using cameras, processors, and algorithms to correct distortion after light has passed through the windshield, the method uses precise physical alignment of the glass sheets' corrugation profiles during manufacturing. This mechanical alignment at the optical path level creates a passive, vibration-resistant correction that eliminates the need for active electronic compensation systems
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 significantly reduces the effect of optical distortion, enhancing image clarity and precision for cameras and other optical devices by treating the windshield as a single optical unit with aligned corrugation profiles.
Implementation Method 1
When a light beam passes through the windshield, the incident light beam and the exiting light beam are parallel to each other, and therefore no small distortion is generated in an image acquired by, for example, a camera or the like through the windshield
Data Source
AI summary
A method is for manufacturing laminated glass (100). The method includes: cutting a first glass (100a) and a second glass (100b) out of one sheet of glass having a corrugation formed in a predetermined direction (W), in such a manner that corresponding sides of the first glass and the second glass are cut in a same cutting direction; and bonding the first glass (100a) and the second glass (100b) together in such a manner that the corrugation of the first glass (100a) and the corrugation of the second glass (100b) are aligned with each other.