Thermoplastic Copolymer Encapsulants for Vehicle Window Bonding

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Solution Overview

Problem

Conventional window assembly encapsulants, such as TPE and RIM, face limitations including poor adhesive bonding with vehicle body adhesives, lack of structural strength, high production costs, and environmental concerns, restricting design flexibility and sustainability.

Innovation Solution

A window assembly using a copolymer of amorphous and crystalline thermoplastic polymers as encapsulants, which allows for strong bonding with adhesives and vehicle bodies, supports structural components, and is environmentally friendly, with the encapsulant comprising thermoplastic polyesters and polyethers, and renewably-sourced materials like PHA resin.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional thermoplastic encapsulants (TPE) are used, then the encapsulant provides basic sealing function, but adhesive material cannot bond to the encapsulant, requiring auxiliary fasteners or exposing transparent pane for adhesive bonding

Engineering Contradiction:

Improvedesign flexibilityVSAvoidauxiliary fasteners

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent modifies the chemical composition parameters of the encapsulant by incorporating specific functional groups (hydroxyl, carboxyl, amine, or isocyanate groups) that enable direct adhesive bonding. This parameter change allows the encapsulant to serve dual functions: sealing and adhesive bonding substrate, eliminating the need for auxiliary fasteners or exposed glass portions.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The encapsulant is designed to perform multiple functions simultaneously: it provides sealing, acts as an adhesive bonding substrate for the adhesive material, and serves as a structural component. This multi-functionality eliminates the need for separate auxiliary fasteners and simplifies the overall window assembly design.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If conventional thermoplastic encapsulants (TPE) are used, then the encapsulant provides sealing function, but it lacks structural strength to support window assembly support members

Engineering Contradiction:

Improvestructural strengthVSAvoiddesign choices

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent creates a composite encapsulant material by combining thermoplastic polymer with reactive functional groups that provide both structural strength and adhesive bonding capability. This composite structure enables the encapsulant to mechanically support window assembly components while maintaining design flexibility.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The encapsulant's chemical composition is modified by incorporating functional groups (hydroxyl, carboxyl, amine, or isocyanate) that enhance both structural properties and bonding capabilities, allowing it to support structural members while providing versatile design options.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If reaction injection molded (RIM) encapsulants are used, then the encapsulant provides adequate performance, but production requires significant capital expense and handling of hazardous components

Engineering Contradiction:

Improveencapsulant performanceVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive RIM encapsulants with a more economical thermoplastic-based encapsulant that achieves comparable performance. This substitution reduces capital equipment requirements and eliminates the need to handle hazardous isocyanates, while maintaining adequate encapsulant performance through the use of reactive functional groups.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent substitutes the complex RIM chemical reaction system with a simpler thermoplastic processing system that uses reactive functional groups for bonding. This replacement reduces manufacturing complexity, capital equipment needs, and hazardous material handling requirements while maintaining encapsulant performance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of manufacture

If PVC encapsulants are used, then production cost is reduced, but the material is chlorinated and not environmentally friendly, requiring special recycling handling

Engineering Contradiction:

Improveproduction costVSAvoidenvironmental impact

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent modifies the chemical composition by replacing chlorinated PVC with thermoplastic polymers containing reactive functional groups. This parameter change maintains production cost-effectiveness while eliminating environmental harm and simplifying recycling requirements.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP2938509B1Encapsulants for window assemblies

Publication Date: 2017.12.20 AGC AUTOMOTIVE AMERICAS R&D INC

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AI summary

A window assembly (10) includes a transparent pane (12) and an encapsulant (22) bonded to the transparent pane (12), wherein the encapsulant (22) is a copolymer of at least one amorphous thermoplastic polymer and at least one crystalline thermoplastic polymer. The at least one amorphous thermoplastic polymer is either at least one thermoplastic polyester, at least one thermoplastic polyether, or a copolymer of at least one thermoplastic polyester and at least one thermoplastic polyether. The at least one crystalline thermoplastic polymer may be a renewably-sourced thermoplastic polymer, wherein the total weight of the renewably-sourced thermoplastic polymer is at most 60 percent of the total weight of the copolymer.