Universal Wedge Layer for HUD Windshield Double Image Compensation
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Solution Overview
Problem
The high cost of manufacturing HUD-compatible windshields is due to the expense of wedge-shaped PVB sheets and the need for a variety of specific sheets for different car models, which increases production costs.
Innovation Solution
A method using a universal wedge layer with a monotonously changing thickness profile to accommodate different windshield models, allowing the same layer to be adapted in size and position to provide the appropriate wedge angle for compensating double images, reducing the need for multiple PVB sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a wedge-shaped PVB sheet is used to compensate double images in HUD windshields, then the image quality is improved, but the manufacturing cost increases significantly
Solution Approach 1:
The patent applies a universal wedge layer with a monotonously changing wedge angle profile that can serve multiple windshield models. This single layer design replaces the need for multiple custom wedge-shaped PVB sheets, achieving both image quality compensation and cost reduction by making the wedge layer universally applicable across different vehicle models.
Solution Approach 2:
The patent changes the wedge angle parameter from a fixed value to a monotonously changing profile across the windshield surface. This parameter variation allows a single wedge layer to provide appropriate compensation for different viewing positions and driver heights, resolving the contradiction between maintaining precise image quality and reducing manufacturing complexity.
2Adaptability or versatility
If different PVB sheets are ordered for each windshield model, then the specific requirements of each model are met, but the manufacturing cost increases due to diversity
Solution Approach 1:
The universal wedge layer is designed to accommodate multiple windshield models through its monotonously changing wedge angle profile. This single versatile component replaces the need for maintaining inventory of multiple model-specific PVB sheets, achieving both adaptability to different models and reduction in manufacturing costs through standardized production.
Solution Approach 2:
The wedge layer is designed as a continuous gradient structure that can be segmented or cropped to fit different windshield models. This segmentation capability allows the same universal layer to be adapted to various model requirements without requiring completely different sheets for each model.
3Ease of manufacture
If a constant wedge angle is used for all driver heights, then the manufacturing process is simplified, but the image compensation is not optimal for all users
Solution Approach 1:
The patent transitions from a constant wedge angle parameter to a monotonously changing wedge angle profile. This parameter variation along the windshield surface enables optimal image compensation for different driver heights and viewing positions while maintaining manufacturing simplicity through a single universal layer design.
Solution Approach 2:
The wedge layer provides locally optimized wedge angles at different positions on the windshield. Each region of the universal layer has a specific wedge angle tailored to compensate for double images at that particular location and viewing angle, achieving high precision image compensation across the entire windshield surface.
Data Source
AI summary
Method for producing a HUD compatible windshield comprising a HUD viewing field (13), said windshield comprising a wedge layer (15) made from a universal wedge layer (14), said universal wedge layer (14) comprising a portion (12) with a thickness profile having a monotonously changing wedge angle wherein said profile comprises a range of wedge angles encompassing wedge angle values adapted to different windshield models, said universal wedge layer (14) having dimensions different from the dimensions of said windshield, said method comprising the following step of: Adapting the dimensions of the universal wedge layer (14) to size said wedge layer (15), wherein said adapting is such that said wedge layer (15) the dimensions of said windshield and such that the wedge angle (W1, W2) at the centre (X1, X2) of the HUD viewing field is appropriate for compensating the double images occurring in reflection at outside and inside surfaces (8, 9) of the windshield at the centre (X1, X2) of said HUD viewing field (13).