Window Distortion Removal by In-Situ Dual-Side Heating
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Solution Overview
Problem
Transparent substrates such as windows and windshields in vehicles often suffer from damage-induced optical distortion, requiring costly and time-consuming replacement processes when repair is needed, as existing methods do not allow for in-situ correction.
Innovation Solution
A method involving controlled heating of both sides of the transparent substrate using heat sources and sensors, maintaining temperatures between 60°F to 167°F for specific durations to reduce or eliminate distortion while the substrate remains in its installed position, utilizing heat blankets and heat guns in conjunction with thermocouples for temperature monitoring and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If windows and windshields are replaced when damaged, then optical distortion is eliminated, but maintenance time and cost increase
Solution Approach 1:
The patent applies thermal energy to change the physical state of the transparent substrate by heating it to a specific temperature range (150°F to 250°F). This temperature change allows the substrate material to become pliable and return to its original shape, eliminating optical distortion without requiring replacement. The controlled parameter change (temperature) enables in-situ repair, significantly reducing maintenance time while restoring optical clarity.
2Manufacturing precision
If windows and windshields are replaced when damaged, then optical distortion is eliminated, but operational disruption increases
Solution Approach 1:
The patent enables the transparent substrate to self-correct its distortion through controlled heating. The substrate, when heated to the appropriate temperature range, automatically returns to its original undistorted shape without requiring removal from the vehicle or complex replacement procedures. This self-service capability allows repairs to be performed quickly in-situ, minimizing vehicle downtime and maintaining operational productivity.
3Strength
If replacement is used for damaged substrates, then structural integrity is restored, but cost increases
Solution Approach 1:
The patent uses controlled thermal parameter changes to restore the transparent substrate's structural integrity. By heating the substrate to a specific temperature range (150°F to 250°F), the material becomes pliable and returns to its original shape, eliminating both optical distortion and structural weakness. This approach preserves the existing substrate rather than requiring replacement, significantly reducing maintenance costs while restoring full structural integrity.
4Loss of time
If in-situ repair is implemented, then maintenance time is reduced, but temperature control complexity increases
Solution Approach 1:
The patent incorporates temperature sensors and controllers that provide feedback to maintain the substrate within the optimal temperature range (150°F to 250°F). This feedback system automatically adjusts heating elements to prevent overheating or underheating, simplifying the operation for the user while ensuring safe and effective repair. The automated temperature control reduces the burden on operators despite the added 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
This approach effectively reduces or eliminates distortion in transparent substrates by restoring their original optical clarity and shape in situ, reducing maintenance time and costs by allowing for on-site repair without removing the substrates from their structural integration.
Implementation Method 1
increasing the surface temperature of the first and second sides of the transparent substrate in situ to a predetermined temperature
Implementation Method 2
maintaining the surface temperature of the first and second sides of the transparent substrate at predetermined temperatures for predetermined durations
Data Source
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AI summary
The invention concerns a method comprising following steps: contacting a first heat source to a first side of a transparent substrate, said transparent substrate comprising an amount of distortion, said first heat source in communication with a first controller; positioning a second heat source at a predetermined distance from a second side of the transparent substrate, said second heat source in communication with the first or a second controller; activating the first and second heat sources; increasing the surface temperature of the first and second sides of the transparent substrate in situ to a predetermined temperature; maintaining the surface temperature of the first and second sides of the transparent substrate at predetermined temperatures for predetermined durations; and reducing distortion in the transparent substrate in situ.