Solar Control Assembly for Automotive Plastic Window Panels
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Solution Overview
Problem
Transparent plastic panels with stylized ink layers or overmolded frames in automotive applications experience surface temperature variations due to solar energy absorption, leading to potential warping and reduced weatherability and operating life.
Innovation Solution
A window assembly with solar control properties, comprising a substrate, a plasma layer, a weathering film layer, and a solar control assembly that includes a solar control system and plastic film layers, along with bonding and adhesion promoting layers, to minimize solar energy absorption and enhance UV protection and weatherability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a stylized ink layer or overmolded frame is added to the transparent plastic panel, then the vehicle design complexity is reduced and styling is improved, but the surface temperature of the panel increases due to solar energy absorption
Solution Approach 1:
A solar control assembly is introduced as an intermediary layer between the transparent panel and the stylized ink layer/overmolded frame. This assembly includes solar control coatings or films that selectively reflect or absorb solar radiation, preventing heat from reaching the panel while allowing the stylized appearance to be maintained.
Solution Approach 2:
The window assembly is constructed as a composite structure with multiple layers including the transparent panel, solar control assembly, and stylized ink layer or overmolded frame. Each layer performs a specific function: the transparent panel provides visibility, the solar control assembly manages thermal properties, and the stylized layer provides aesthetic appearance.
2Device complexity
If a stylized ink layer or overmolded frame is added to the transparent plastic panel, then the vehicle design complexity is reduced and styling is improved, but the panel experiences warping after cooling
Solution Approach 1:
The solar control assembly acts as a thermal buffer between the stylized ink layer/overmolded frame and the transparent panel. By controlling solar heat absorption at this intermediary layer, the panel is protected from excessive temperature variations that cause thermal expansion and subsequent warping upon cooling.
3Device complexity
If a stylized ink layer or overmolded frame is added to the transparent plastic panel, then the vehicle design complexity is reduced and styling is improved, but the weatherability and operating life of the panel are reduced
Solution Approach 1:
The solar control assembly serves as a protective intermediary that filters harmful solar radiation before it reaches the stylized ink layer or overmolded frame. This reduces UV degradation and thermal stress on these layers, thereby improving the overall weatherability and extending the operating life of the window assembly.
4Temperature
If solar control assembly is added to minimize solar energy absorption, then surface temperature variations are reduced and weatherability is improved, but the device complexity increases
Solution Approach 1:
The solar control assembly is designed to perform multiple functions simultaneously: it controls solar heat absorption, provides UV protection, and can be integrated with the stylized ink layer or overmolded frame structure. This multi-functionality reduces the need for separate components, thereby limiting the increase in overall device complexity.
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 surface temperature variations, improves weatherability, and extends the operating life of transparent plastic panels by minimizing solar energy absorption and providing excellent UV protection.
Implementation Method 1
a solar control assembly located between the first side of the substrate and the weathering film layer, the solar control assembly further comprising a solar control system
Implementation Method 2
minimize the amount of solar energy collected in portions of a transparent panel having a stylized ink layer or overmolded frame
Implementation Method 3
a first plasma layer adjacent to the first side of the substrate
Implementation Method 4
a first plasma layer adjacent to the first side of the substrate
Implementation Method 5
a weathering film layer located between the first side of the substrate and the plasma layer
Data Source
Figure 1
Figure 2~3
Figure 4~5B
AI summary
The invention concerns a window assembly (14c,14d) having solar control properties, the assembly comprising: a substrate (32) having a first side (34) and a second side (36); a first plasma layer (58) adjacent to the first side (34) of the substrate (32); a weathering film layer (66) located between the first side (34) of the substrate (32) and the plasma layer (58); and characterized by a solar control assembly (40c,40d) located between the first side (34) of the substrate (32) and the weathering film layer (66), the solar control assembly (40c,40d) further comprising a solar control system (42) and a plastic film layer (46); and an ink layer (38) located between the first side (34) of the substrate (32) and the solar control assembly (40c,40d) and/or an overmolded black component (68) located between the second side (36) of the substrate (32) and a second plasma layer (60) surrounding the periphery of the substrate (32); wherein the solar control assembly (40c,40d) further comprises one of a) a first bonding layer (50) located between the solar control system (42) and the plastic film layer (46) and a second bonding layer (48) located between the solar control system (42) and the weathering film layer (66), wherein the bonding layers (48, 50) attach the solar control system (42) to the plastic film layer (46) and the weathering film layer (66), and b) a first adhesion promoting layer (51) located between the solar control system (42) and the plastic film layer (46) and a second adhesion promoting layer (49) located between the solar control system (42) and the weathering film layer (66), wherein the adhesion promoting layers (49, 51) attach the solar control system (42) to the plastic film layer (46) and the weathering film layer (66) respectively.