Heatable Vehicle Glazing Insert for Clear Sensor Windows
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Solution Overview
Problem
Modern vehicles equipped with increasing numbers of optical sensors on windshields face challenges such as optical distortions and glass breakage during the bending process, and existing solutions like laminated heating wires compromise optical quality.
Innovation Solution
A vehicle composite window design featuring a thermoplastic intermediate layer with an insert element comprising an opaque layer, a transparent substrate layer, and a transparent electrically heatable layer, which can be arranged in various sequences to minimize the risk of glass breakage and maintain optical quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heating wires are laminated into the sensor window area, then the sensor window can be heated to prevent ice or fog formation, but the optical quality of the sensor window deteriorates
Solution Approach 1:
The heating function is extracted from the sensor window area and transferred to the opaque masking print layer. The masking print is made electrically conductive and heating-capable, allowing it to be heated independently while the sensor window remains optically clear and free of heating wires or transparent conductive coatings that would degrade optical quality.
Solution Approach 2:
The opaque masking print serves as an intermediary element that performs the heating function. Instead of placing heating elements directly in the sensor window, the masking print acts as a mediator that can be heated to transfer thermal energy to the sensor window area through conduction and radiation, while maintaining optical clarity in the sensor window.
2Ease of manufacture
If the masking print is applied before bending, then the bending process can be performed, but the heat absorption causes optical distortions in sensor windows and glass breakage
Solution Approach 1:
The thermal properties of the masking print are modified by making it electrically conductive. This allows controlled heating through electrical current rather than relying on passive heat absorption during bending. The heating can be precisely controlled in terms of temperature, duration, and distribution, preventing excessive heat absorption that causes optical distortions and glass breakage.
Solution Approach 2:
The masking print is prepared with electrical conductivity and heating capability before the bending process. This preliminary preparation allows the masking print to actively manage heat during subsequent operations, preventing the uncontrolled heat absorption that occurs with conventional non-conductive masking prints during bending and other manufacturing processes.
3Adaptability or versatility
If multiple sensors are attached to the windshield, then more detection functions are available, but the sum of sensor windows occupies more surface area and requires greater covering pressure
Solution Approach 1:
The masking print is designed to cover multiple sensor windows simultaneously with a single continuous or interconnected opaque layer. This merging approach consolidates the covering function for multiple sensors into one unified structure, reducing the total amount of masking material needed and simplifying the overall design while maintaining concealment of multiple sensors.
Solution Approach 2:
The opaque masking print serves multiple functions: it conceals multiple different types of sensors (cameras, LIDAR, rain sensors), provides UV protection for the adhesive, and acts as a heating element. This multi-functionality allows a single structure to address multiple requirements, reducing the need for separate components for each function and optimizing the use of windshield surface area.
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
The solution effectively reduces the risk of glass breakage during the bending process while maintaining or improving the optical quality of sensor windows, enabling efficient heating to prevent ice or fog formation.
Implementation Method 1
the transparent electrically heatable layer heats up when a voltage is applied
Implementation Method 2
a first pane and a second pane which are connected to one another via at least one thermoplastic intermediate layer
Data Source
Figure 1~2
Figure 3~4
Figure 5~8
AI summary
The present invention relates to a vehicle composite pane (1), at least comprising a first pane (2) and a second pane (3), which are joined together by at least one thermoplastic intermediate layer (4), and an inlay element (5), which is provided between the first pane (2) and the second pane (3). The inlay element (5) comprises an opaque layer (6), which has at least one cut-out (8), a transparent substrate layer (7), and a transparent electrically heatable layer (9).