Window Primer Color Matching Thermoplastic Encapsulation
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Solution Overview
Problem
Conventional primers for window assemblies with thermoplastic encapsulations do not blend with the ceramic frit, leading to a poor aesthetic appearance and increased manufacturing costs when using thermoset materials, as they are more costly than thermoplastic materials.
Innovation Solution
A window assembly design where a primer with a Delta-E value less than 5 is used, matching the color of the ceramic frit, and positioned between the ceramic frit and the edge of the transparent pane, allowing a thermoplastic encapsulation to cover both, ensuring a cohesive and aesthetically pleasing appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional primers are used with thermoplastic encapsulation, then manufacturing costs are reduced, but the primer color does not blend with ceramic frit leading to poor aesthetic appearance
Solution Approach 1:
The primer is formulated to have a color that matches the black ceramic frit, specifically with color coordinates L*=-2.5 to 2.5, a*=-3.0 to 3.0, and b*=-3.0 to 3.0. This color matching eliminates the visual discrepancy between primer and ceramic frit, achieving aesthetic appearance comparable to expensive thermoset encapsulations while using cost-effective thermoplastic materials.
Solution Approach 2:
The primer's chemical composition is modified to include specific pigments and additives that enable color matching with black ceramic frit. By changing the primer's physical and chemical parameters, particularly its color properties, the invention resolves the contradiction between using inexpensive thermoplastic material and achieving aesthetic appearance.
2Device complexity
If thermoset encapsulation material is used, then aesthetic appearance is improved with black primer blending, but manufacturing costs increase
Solution Approach 1:
The invention replaces expensive thermoset encapsulation material with cheaper thermoplastic material. By compensating for the cost difference through primer color matching technology rather than material substitution, the invention achieves similar aesthetic appearance at lower manufacturing cost.
Solution Approach 2:
The primer serves as an intermediary element that bridges the visual gap between the transparent pane and the thermoplastic encapsulation. By making the primer color match the black ceramic frit, it mediates the aesthetic appearance, allowing thermoplastic material to achieve the same visual effect as thermoset material.
3Device complexity
If primer color is made to match ceramic frit, then aesthetic appearance is improved, but primer visibility on transparent pane may increase
Solution Approach 1:
The primer is applied selectively to specific areas where it is needed for bonding and aesthetic purposes. The primer is positioned between the transparent pane and the encapsulation, and extends to cover the bonding area, ensuring it is visible only where necessary for structural and aesthetic functions, not across the entire pane.
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
The solution provides a window assembly with improved aesthetic appeal and reduced manufacturing costs by using thermoplastic materials while maintaining the black color of the ceramic frit, enhancing the bond strength and visibility integration.
Implementation Method 1
The encapsulation is bonded to the perimeter of the transparent pane via the primer. Said differently, the encapsulation bonds to the primer, which is bonded to the transparent pane, thereby bonding the encapsulation to the transparent pane.
Implementation Method 2
The ceramic frit has a color, which is typically referred to as black, for absorbing solar energy and impeding the solar energy from penetrating the window assembly. Preventing the solar energy from penetrating the window assembly prevents degradation of chemical and physical properties of the primer
Implementation Method 3
The conventional primers used with the thermoplastic material provide an adhesive bond and do not chemically react with the thermoplastic material of the encapsulation. More specifically, the conventional primers used with the thermoplastic material are typically long chain polymers that only mix with the thermoplastic material, which results in polymer chain entanglement.
Data Source
Figure 1~4
Figure 5~6
AI summary
A window assembly is used in a vehicle. The window assembly comprises a transparent pane having an inner surface and an outer surface spaced from the inner surface. The window assembly also comprises a ceramic frit disposed on a portion of the transparent pane. A primer is disposed on at least one of the transparent pane and the ceramic frit for providing a bonding surface. An encapsulation is coupled to the primer.