Automotive Window Laminate Structure Without Separate Frame Layers
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Solution Overview
Problem
Current thermoplastic laminated sheet structures for automotive windows face challenges with optical performance, strength, and weight due to the use of ethylene-vinyl acetate (EVA) bonding layers, and the need for additional frame layers to fill gaps around functional layers, which complicates production and increases weight.
Innovation Solution
An automotive window laminate structure with a thermoplastic laminated sheet comprising a functional layer covered by bonding layers, where the encapsulation layer is formed by an inactive portion of the functional layer, reducing the need for a separate frame layer and allowing easier production by eliminating the requirement for precise positioning of a frame layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If EVA bonding layer is used, then bonding properties with plastics are improved, but optical performance deteriorates (hazy and opaque with optical distortion)
Solution Approach 1:
The patent combines the bonding layer and encapsulation layer into a single integrated EVA layer. The bonding layer portion provides adhesion between glass sheets and thermoplastic layers, while the encapsulation layer portion seals the functional layer perimeter, eliminating the need for a separate frame layer and reducing optical distortion from multiple layer interfaces.
Solution Approach 2:
The EVA layer serves multiple functions simultaneously: it acts as a bonding agent between glass and thermoplastic layers, provides encapsulation for the functional layer perimeter, and fills gaps between layers. This multi-functionality reduces the number of separate components needed and simplifies the overall structure.
2Strength
If thicker PET layer is used to compensate for low EVA strength, then strength is improved, but weight increases significantly
Solution Approach 1:
The patent merges the bonding function and encapsulation function into a single EVA layer, eliminating the need for additional frame layers or thicker structural layers that would increase weight. The integrated design provides both strength and sealing without requiring excess material.
3Illumination intensity
If PVB is used as bonding layer, then optical performance and strength are improved, but ability to level out openings/gaps deteriorates due to higher viscosity
Solution Approach 1:
The patent changes the viscosity parameter of the bonding layer by selecting EVA instead of PVB. EVA's lower viscosity at processing temperature enables it to flow into and fill gaps between layers effectively, while still providing adequate bonding strength and optical performance when properly formulated.
4Reliability
If separate frame layer is used to encapsulate functional layer, then sealing effectiveness is improved, but device complexity and production difficulty increase
Solution Approach 1:
The patent merges the bonding layer and encapsulation layer into a single integrated EVA layer. This eliminates the need for a separate frame layer, reducing the number of components from two to one, and simplifying production by eliminating the precise positioning step required for separate frame layers.
Solution Approach 2:
The EVA layer serves multiple functions simultaneously: it acts as a bonding agent between glass and thermoplastic layers, provides encapsulation for the functional layer perimeter, and fills gaps between layers. This multi-functionality reduces the number of separate components needed and simplifies the overall structure.
5Manufacturing precision
If precise positioning of frame layer is required, then encapsulation effectiveness is improved, but manufacturing time and complexity increase
Solution Approach 1:
The patent merges the bonding layer and encapsulation layer into a single integrated EVA layer applied as one continuous operation. This eliminates the need for separate positioning and alignment steps between distinct frame layer and bonding layer components, thereby improving production efficiency while maintaining encapsulation effectiveness.
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 solution enhances the production efficiency of automotive window laminates by eliminating the need for a separate encapsulation layer, improving optical performance, and reducing weight while maintaining structural integrity and sealing effectiveness.
Implementation Method 1
The present invention is related to an automotive window laminate structure, comprising a first glass sheet, and a second glass sheet, said first and second glass sheet are parallel and mutually spaced apart, a thermoplastic laminated sheet structure, said laminated sheet structure substantially entirely placed between the first and second glass sheet
Implementation Method 2
an encapsulation layer, which encapsulation layer extends along at least a portion of the perimeter of the functional layer, wherein at least a part of the encapsulation layer is formed by an inactive portion of the functional layer
Data Source
AI summary
An automotive window laminate structure, including first and second parallel and mutually spaced apart glass sheets and a thermoplastic laminated sheet structure. The laminated sheet structure is placed between the first and second glass sheet, and the laminated sheet structure includes at least one functional layer with an upper and lower surface, at least two bonding layers, with the bonding layers covering the upper and lower surfaces of the functional layer. A portion of the bonding layers extends beyond the perimeter of the functional layer and an encapsulation layer is located between the first and second glass sheet, such that the encapsulation layer extends along the perimeter of the functional layer.