Laminated Glass Conductive Layer Frost Removal

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Solution Overview

Problem

Existing methods for removing frost or cloudiness from glasses, such as blowing hot air or forming conductive layers in laminated glasses, face issues like inefficiency, disconnection, detachment, and deformation due to thermal shrinkage and differences in thermal expansion rates, leading to reduced visibility and heat-generating performance, especially in electric vehicles.

Innovation Solution

A laminate comprising a base material film, a resin layer with a detachable surface, and a heat-generating conductive layer, where the resin layer is thin and has a specific surface roughness, and the conductive layer includes copper with main and auxiliary fine wires arranged in a specific pattern to minimize disconnection and deformation, ensuring excellent visibility and heat-generating properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If a thin-film polyvinyl acetal resin film is used as the base material for the conductive layer, then the laminate can be made thin and flexible, but the conductive layer undergoes disconnection, detachment, and deformation due to thermal shrinkage and difference in thermal expansion rate

Engineering Contradiction:

Improvethickness of laminateVSAvoidintegrity of conductive layer

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent uses a composite structure consisting of a polyvinyl acetal resin film (base material) and a copper foil (conductive layer). This composite material approach allows the laminate to maintain both thinness and flexibility while the copper foil provides dimensional stability to prevent disconnection and deformation of the conductive pattern during thermal processing and operation.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If an etching treatment is carried out to form the conductive layer pattern, then the desired current-conducting structure can be created, but the thin-film polyvinyl acetal resin film undergoes warpage and deformation during the drying step

Engineering Contradiction:

Improveability to form conductive patternVSAvoidflatness of resin film

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies a primer coating to the polyvinyl acetal resin film before forming the copper conductive layer. This preliminary action enhances the adhesion between the resin film and copper foil, preventing warpage and deformation during the etching drying step. The primer layer acts as an intermediate that stabilizes the film structure during subsequent processing.

Inventive Principle:

Principle #10Preliminary action

3Power

If the conductive layer is made with copper foil and etching treatment, then good electrical conductivity is achieved, but the appearance of the laminate is deteriorated and mechanical disconnection occurs before laminated glass formation

Engineering Contradiction:

Improveelectrical conductivity of conductive layerVSAvoidstructural integrity before lamination

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The patent applies a protective coating over the copper conductive layer after etching. This preliminary protective measure prevents mechanical disconnection and detachment of the conductive pattern before the laminated glass is formed. The coating also protects the copper from oxidation and maintains the aesthetic appearance of the laminate.

Inventive Principle:

Principle #10Preliminary action

4Temperature

If hot air is blown onto the glass to remove frost or cloudiness, then the glass can be heated, but it takes time to achieve satisfactory front visibility and reduces drive distance in electric vehicles

Engineering Contradiction:

Improvetemperature of glass surfaceVSAvoidtime to clear frost

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

The patent replaces the mechanical hot air blowing system with an electrical heating system. A conductive layer (copper foil with patterned conductive paths) is embedded in the laminate, allowing direct electrical heating of the glass surface. This substitution of mechanical convection heating with electrical conduction heating significantly reduces the time required to clear frost while improving energy efficiency for electric vehicles.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 laminate prevents disconnection, detachment, and deformation of the conductive layer, achieving excellent visibility and heat-generating performance in laminated glasses, even under mechanical stress, and enhances the efficiency of frost removal.

Implementation Method 1

a method in which the frost or cloudiness are removed by forming a conductive layer between glasses in a laminated glass and then allowing an electric current to pass through the conductive layer

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

the disconnection, detachment, deformation or the like occurs in a current-conducting structure in association with the thermal shrinkage of a thin-film polyvinyl acetal resin film

Methodology Applied

Scientific EffectThermal shrinkage: Thermal Contraction