Laminated Glazing With Overmolded Component Integration
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Solution Overview
Problem
Integrating thick components into laminated glazing with polyvinyl butyral (PVB) adhesive sheets between glass sheets is challenging due to PVB's poor ability to flow over large distances, leading to deformation, bubbling, and optical distortion, as well as increased costs and defects from multiple PVB interfaces.
Innovation Solution
A method for assembling laminated glazing with an overmolded component involves precutting a window in the adhesive sheet, positioning the component within, and spot welding it to maintain contact with the sheet's side walls, followed by adding additional glass and welding, ensuring a homogeneous PVB film and minimizing interfaces to prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If thick components are integrated into laminated glazing, then component functionality is improved, but PVB flow ability deteriorates causing bubbling and deformation
Solution Approach 1:
The PVB adhesive sheet is precut with a window shape before assembly to accommodate the thick component. This preliminary action allows the PVB to flow only to the boundaries of the window during autoclaving, preventing excessive flow distance and avoiding bubbling while still enabling thick component integration.
Solution Approach 2:
The PVB adhesive sheet is segmented into different regions: a window-shaped opening for the component and surrounding adhesive regions. This segmentation allows the PVB to concentrate its flow in specific areas rather than attempting to flow over the entire component, maintaining reliability while accommodating thick components.
2Adaptability or versatility
If thick components are placed between glass sheets, then component functionality is improved, but optical quality deteriorates due to deformation
Solution Approach 1:
The window is precut in the PVB sheet to match the component footprint, allowing the component to be positioned precisely without causing excessive local deformation. The PVB flows only to the window boundaries, maintaining flat glass surfaces and optimal optical quality.
Solution Approach 2:
The PVB adhesive is strategically positioned around the component rather than covering it entirely. The window-shaped opening creates a local adaptation zone that accommodates the thick component while the surrounding PVB maintains uniform thickness and optical quality in the visible glass areas.
3Adaptability or versatility
If multiple PVB sheets are used to accommodate thick components, then component integration is improved, but manufacturing complexity increases
Solution Approach 1:
Instead of using multiple separate PVB sheets, the invention segments a single PVB sheet by precutting a window shape. This approach achieves the same functional result as multiple sheets (accommodating thick components) while reducing the number of interfaces from multiple PVB-PVB boundaries to a single continuous PVB layer.
Solution Approach 2:
The invention merges the functions of multiple PVB sheets into a single precut PVB sheet. The window-shaped opening in one sheet replaces the need for multiple sheets stacked together, simplifying the assembly process and reducing manufacturing complexity while still accommodating thick components effectively.
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 results in a product with reduced optical distortion, minimized bubbling, and lower defect rates, maintaining transparency and quality while allowing for thicker components without excessive deformation or breakage, suitable for industrial production.
Implementation Method 1
it is known that in the assembly and autoclaving process, PVB has difficulty flowing over distances greater than a few millimeters
Implementation Method 2
spot welding it to the sheet in such a way that the lateral walls of the window and of the component remain in contact
Data Source
Figure 1a~1b
Figure 2~3
Figure 4~5
AI summary
The invention relates to – a method of assembling a laminated glazing (1), in which – an overmoulded component (10; 11) is placed inside an opening cut in an adhesive sheet (4); – the overmoulded component (10; 11, 4d) and the precut adhesive sheet (4, 4e) are spot-welded (5) to a first sheet of glass (2) in the vicinity of the opening so that the lateral walls of this opening and of the overmoulded component (10; 11, 4d) remain contiguous, – the adhesive sheet (4, 4e) and a second sheet of glass (3) are spot-welded (6); and – the laminated glazing (1) is assembled by implementing suitable temperatures and pressures in the usual way; – a laminated glazing (1) obtained by this method and the application thereof to a transport vehicle, to buildings, to street furniture or to interior fixtures and fittings.