Interlayer Ply Assembly for Embedded Electronics in Curved Glazing
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Solution Overview
Problem
The existing manufacturing processes for laminated glazing with embedded electronic components face challenges, particularly when inserting circuit boards into curved glass sheets, as it can cause stretching of the plastic ply and adhesive materials, complicating the lamination process.
Innovation Solution
A method involving the use of a liquid adhesive material that solidifies to create a uniform thickness and texture, covering the electronic components, and incorporating a flex circuit for power supply, which simplifies the integration of electronic devices into the laminated glazing by ensuring secure bonding and easy separation for subsequent lamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrical devices are incorporated into textile structures to enable heating and sensing functions, then functionality is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines electrical conductors, insulating layers, and sensing elements into a single integrated textile structure. Multiple functional layers (heating conductors, thermistor elements, insulating plies) are merged into one manufacturable unit, reducing the number of separate components and assembly steps required.
Solution Approach 2:
The textile structure serves multiple functions simultaneously: heating (via conductive elements), sensing (via thermistor elements detecting skin temperature), and insulating (via intermediate plies). This multi-functionality is achieved within a single integrated structure rather than separate components.
2Ease of manufacture
If conventional separate component assembly is used for electrical devices in textiles, then manufacturing flexibility is maintained, but production time increases
Solution Approach 1:
Conductors and functional elements are pre-assembled into intermediate plies during the textile manufacturing process itself, rather than being attached later. The heating conductors are incorporated into the knit structure during knitting, and thermistor elements are embedded in intermediate plies before final assembly, reducing post-manufacturing assembly time.
Solution Approach 2:
The patent uses a nested structure where conductors are embedded within intermediate plies, which are then integrated into the final textile structure. The intermediate plies containing pre-assembled electrical components are nested within the multi-layer textile, enabling efficient manufacturing while maintaining assembly flexibility.
3Adaptability or versatility
If electrical conductors are embedded in textile structures, then functional integration is improved, but structural complexity increases
Solution Approach 1:
Different regions of the textile structure have different properties: intermediate plies contain conductors and thermistor elements for electrical functionality, while other plies provide insulation or structural support. Each layer is optimized for its specific function, with conductors localized to where heating is needed and thermistors positioned for optimal skin temperature sensing.
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 enhances the ease of integrating electronic components into laminated glazing by preventing stretching and ensuring secure bonding, facilitating the lamination process, especially in curved glass applications, and providing reliable electrical connections.
Implementation Method 1
The heating device may include an electrical conductor, such as a resistance wire, that generates heat when an electrical current passes through the resistance wire
Implementation Method 2
The sensing device may include a thermistor element, such as a negative temperature coefficient (NTC) thermistor, that detects skin temperature
Data Source
Figure 1~2
Figure 3a~6b
Figure 7a~12
AI summary
A method of making an electrical device is described. The method comprises the steps:(i) providing a layer of interlayer material having a first major surface and a second opposing major surface;(ii) positioning at least a first electrically operable component on the first major surface of the first layer of interlayer material, the first electrically operable component being mounted on a first circuit board; and(iii) providing a layer of adhesive material, preferably as a liquid,to cover at least a portion of the first major surface of the layer of interlayer material and at least a portion of the first electrically operable component and/or at least a portion of the first circuit board such that following step (iii) the first electrically operable component is fixed on the layer of interlayer material by at least a portion of the layer of adhesive material.