Ultrasonic Wire Integration in Polymer Glass Panels
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Solution Overview
Problem
Existing methods for integrating conductive wires into glazing, such as windshields and rear windows, face challenges in achieving high optical performance and complex geometries, particularly with pronounced and spherical curvatures, due to their complexity and difficulty in production.
Innovation Solution
A method where the conductive wire is partly sunk into a polymer substrate, with a protective coating of primer and anti-scratch varnish, and integrated using ultrasound and pressure, ensuring the wire is at most flush with the surface or protrudes slightly, allowing for high optical performance and ease of manufacturing on complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive wires are completely embedded in polymer substrate, then wire is protected and integrated, but optical performance deteriorates due to full embedding causing distortions
Solution Approach 1:
The conductive wire is partially embedded in the polymer substrate rather than completely embedded. The wire protrudes slightly from the surface (at most flush or with minimal protrusion), providing a balance between integration/protection and optical clarity. This partial embedding resolves the contradiction by achieving sufficient wire integration while maintaining high optical performance.
2Manufacturing precision
If complex geometry glazing is manufactured using traditional wire insertion methods, then complete wire embedding is achieved, but manufacturing complexity increases and productivity decreases
Solution Approach 1:
The invention changes the embedding depth parameter from complete embedding to partial embedding (wire protruding at most flush with surface). This parameter change simplifies the manufacturing process for complex geometry glazing, reducing process steps and increasing productivity while maintaining sufficient wire integration through the partial embedding approach.
3Reliability
If conductive wires are inserted using traditional methods with heat and pressure, then wires are confined between glass sheets, but the process becomes complex with many steps
Solution Approach 1:
The invention extracts the heat and pressure steps from the wire integration process, relying solely on ultrasonic vibration to embed the conductive wire in the polymer substrate. This extraction of unnecessary process steps reduces manufacturing complexity while maintaining reliable wire confinement and integration through the ultrasonic embedding mechanism.
4Ease of manufacture
If wire protrusion from polymer surface is maximized, then wire integration is simplified, but optical performance worsens due to increased protrusion
Solution Approach 1:
The invention applies partial protrusion of the conductive wire from the polymer surface (at most flush or with minimal protrusion). This partial action optimizes the balance between manufacturing simplicity and optical performance, achieving sufficient ease of wire integration while maintaining high optical clarity by limiting the protrusion extent.
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 simplifies the integration of conductive wires into glazing with high optical performance, maintaining minimal yield losses and reducing process steps, while ensuring the wires are not fully embedded, thus avoiding optical distortions and achieving high optical clarity.
Implementation Method 1
the conductive wire is integrated into the glazing by subjecting the conductive wire and a thermoplastic material forming a substrate to the combined action of ultrasound and of a pressure
Data Source
Figure 1~3
Figure 4~5b
AI summary
The invention relates to a glass panel including an integrated conducting wire. The invention is characterized in that one surface of the glass panel comprises: a substrate made from polymer material, into which the conducting wire is partially sunk and at most flush with the surface of said polymer material; or a substrate made from mineral glass or polymer material, to which the conducting wire is affixed. The invention also relates to the method for producing one such glass panel, and to the use of said glass panel for transport vehicles, buildings, street furniture, interior fittings, electrical appliances, or electronics.