UV-Curing Adhesive Laminate for Windshield Crack Protection

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Solution Overview

Problem

Existing windshield repair methods using solvent-cured adhesives often result in incomplete curing and lack of rigidity, leading to ineffective temporary protection against further damage from impacts and environmental factors, causing unnecessary windshield replacements and increased costs.

Innovation Solution

A UV-curing adhesive laminate with a clear, flexible barrier film that forms a rigid substrate connection to the windshield, preventing crack or chip growth through cross-linking without solvent evaporation, using a UV-permeable film and adhesive that cures quickly upon exposure to light.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If solvent-cured adhesive is used to bond the protective film to the windshield, then the adhesive provides initial bonding capability, but the adhesive fails to fully cure and lacks rigidity, resulting in ineffective protection against further damage

Engineering Contradiction:

Improveprotection effectivenessVSAvoidadhesive rigidity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent changes the curing mechanism parameter from solvent evaporation to UV light activation. The adhesive layer contains photoinitiators that trigger polymerization when exposed to UV light, transforming the adhesive from a flexible, uncured state to a rigid, cross-linked structure that provides effective protection against further damage.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the chemical curing process (solvent evaporation) with a physical curing process (UV light exposure). This substitution enables complete and rapid curing of the adhesive, achieving the desired rigidity and protective strength that solvent-based methods fail to deliver.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Object-affected harmful factors

If a clear protective film is applied over the damaged area, then the windshield is protected from further damage, but the adhesive solvent cannot fully evaporate, preventing complete curing

Engineering Contradiction:

Improvecrack propagation protectionVSAvoidcuring time

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The patent replaces the time-dependent solvent evaporation process with an instantaneous UV light curing process. The adhesive cures completely in minutes when exposed to UV light, eliminating the prolonged uncured state that would otherwise persist while the protective film is applied and the solvent slowly evaporates.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The adhesive is formulated with photoinitiators that enable immediate curing upon UV exposure. This preliminary preparation of the adhesive composition allows it to transition rapidly from uncured to fully cured state, providing immediate protection without the delays associated with solvent evaporation.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If the adhesive remains in a non-full cured flexible state, then the film can be applied, but the film lacks rigidity to provide structural integrity and prevent crack growth

Engineering Contradiction:

Improvefilm application flexibilityVSAvoidfilm structural rigidity

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The adhesive is pre-formulated with photoinitiators and designed to remain in a flexible, uncured state during film application. Once the film is positioned on the windshield, UV light exposure triggers immediate cross-linking, transforming the adhesive from flexible to rigid, providing both ease of application and subsequent structural integrity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The adhesive transitions dynamically from a flexible, uncured state during application to a rigid, cross-linked state after UV exposure. This dynamic property change allows the system to satisfy both requirements: flexibility during installation and rigidity for protective function.

Inventive Principle:

Principle #15Dynamics

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

Provides a durable, flexible, and optically clear temporary repair solution that resists impact and stress forces, preventing crack or chip enlargement until permanent repair can be made, reducing replacement costs and environmental waste.

Implementation Method 1

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS8715440B2Method and means for protecting a windshield from further damage before repair is possible

Publication Date: 2014.05.06 NOVATECH FS INC

AI summary

One possible embodiment of the invention could be a methodology of preventing an existing crack or break in the vehicle windshield from becoming larger comprising of the steps, providing a laminate with a UV light-permeable barrier film having least one side to which UV light curable adhesive is applied to it, a peel-able cover reversibly applied over the adhesive; providing a windshield with at least a small crack or chip in its surface; removing the peel-able cover from the adhesive; applying the barrier film to the windshield in a manner to cover the crack or chip so that the adhesive comes in contact with the windshield; and transmitting UV light through the film to the adhesive to cure it into a rigid substrate connection between the barrier film and the windshield that resists various forces acting upon the windshield that would otherwise increase the size of crack or chip.