Induction Bonding Metallic Hardware to Vehicle Glass
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Solution Overview
Problem
In the vehicle manufacturing industry, there is a need for a cost-effective and efficient method to robustly attach various hardware items to vehicle windows without penetrating the glass, while ensuring precise positioning and high-quality assembly with minimal effort on the assembly line.
Innovation Solution
A method and apparatus utilizing induction heating to bond metallic hardware to a glass substrate, where the hardware is brought into contact with the glass using an adhesive and heated directly by induction heating devices, with the glass substrate supported on a conveyor system, allowing for precise positioning and rapid curing of the adhesive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional heating methods are used to bond hardware to glass substrates, then the bonding process can be completed, but the cycle time is extended and production efficiency is reduced
Solution Approach 1:
The patent replaces conventional thermal conduction heating with induction heating technology. The induction heating system uses electromagnetic fields to directly heat the metallic hardware items through eddy currents, eliminating the need for prolonged thermal conduction through the adhesive layer. This substitution of heating mechanism dramatically reduces the bonding cycle time while maintaining bond quality, directly resolving the contradiction between productivity and cycle time.
Solution Approach 2:
The patent changes the heating parameter from low-temperature prolonged heating to high-temperature rapid heating via induction. By controlling the induction heating power and duration, the system achieves rapid curing of the adhesive in a fraction of the time required by conventional methods, thereby improving production efficiency without sacrificing bonding quality.
2Reliability
If hardware items are attached to glass substrates without penetration, then the glass integrity is maintained, but the bonding strength and robustness may be compromised
Solution Approach 1:
The patent utilizes parameter changes in the adhesive material by controlling the curing temperature through induction heating. The adhesive transitions from a viscous state to a cured state with high bonding strength through precise temperature control. This allows achieving strong bonds without penetrating the glass, maintaining both glass integrity and bonding strength.
Solution Approach 2:
The patent employs a composite bonding system consisting of the adhesive material and the metallic hardware item. The induction heating selectively heats the metallic hardware, which then conducts heat to the adhesive, creating a strong bond between the hardware and glass substrate without requiring glass penetration. This composite approach ensures both glass integrity and robust bonding.
3Manufacturing precision
If precise positioning of hardware items is achieved, then assembly quality is improved, but the positioning and alignment process becomes more complex
Solution Approach 1:
The patent implements self-positioning features on the hardware items that utilize the induction heating field and fixture interaction to automatically align and position the items during the bonding process. The metallic hardware items are attracted and positioned by the induction heating coil and fixture geometry, eliminating the need for complex external positioning mechanisms while achieving high manufacturing precision.
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 enables the production of high-quality vehicle window assemblies with robustly attached hardware, reducing cycle time and installation effort, while maintaining the integrity of the glass substrate, thus meeting the demands of vehicle manufacturers for advanced, cost-effective solutions.
Implementation Method 1
activating one or more induction heating devices to heat the metallic item of hardware directly
Implementation Method 2
The system uses alternating magnetic fields that induce eddy currents and generate heat within susceptors
Implementation Method 3
heating the glass substrate; characterised by the item of hardware being metallic; and by activating one or more induction heating devices to heat the metallic item of hardware directly, and accelerate curing of the adhesive material
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
A method and apparatus for forming a vehicle window assembly utilizes one or more induction heating devices to adhesively bond an item of hardware to a glass substrate, which substrate is then adapted to fill an opening in a vehicle body. Preferably, the induction heating device(s) and one or more assembly aids are components of an assembly fixture which allows for automated or semi-automated production of such vehicle window assemblies.