Windshield Bonding with Shape Memory Alloy Removal Wires
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Solution Overview
Problem
The removal of armored windshields from their frames is a time-consuming and potentially damaging process due to the strong adhesive used, requiring tools to break and pull the windshield out.
Innovation Solution
A system called POPSY, which uses a layer of bonding material with embedded shape memory wires (popwires) and a heating element to soften the adhesive, allowing the popwires to transition and generate force to push the windshield out of the frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a strong adhesive is used to bond the windshield securely in place, then the bonding strength is improved, but the ease of removal deteriorates
Solution Approach 1:
The patent incorporates a heating element and shape memory alloy wire into the adhesive layer before bonding. The heating element is activated during removal to heat the adhesive, and the shape memory wire is programmed to expand at a specific temperature, automatically pushing the windshield out. This preliminary integration of removal mechanisms resolves the contradiction by preparing the removal action in advance without compromising the initial strong bonding.
Solution Approach 2:
The patent uses a shape memory alloy wire that changes its physical parameters (expands) in response to temperature changes. The adhesive is heated to a specific temperature range that triggers the phase transition of the shape memory alloy, causing it to expand and push the windshield out. This parameter change approach allows the same system to maintain strong bonding at normal temperatures while enabling easy removal when heated.
2Ease of operation
If the adhesive is heated to remove the windshield, then the ease of removal is improved, but the risk of ignition and damage increases
Solution Approach 1:
The patent exploits the phase transition properties of shape memory alloys, which undergo a reversible transformation between martensite and austenite phases at specific temperatures. The heating element is controlled to heat the adhesive to a temperature sufficient to trigger this phase transition and expand the wire, but below the ignition temperature of the adhesive. This phase transition mechanism provides a predictable and controllable removal process that avoids harmful ignition.
Solution Approach 2:
The patent incorporates a controller that monitors the heating process and regulates the heating element to maintain temperatures below the ignition point of the adhesive. This feedback control ensures that the adhesive is heated sufficiently to activate the shape memory wire expansion while preventing overheating that could cause ignition or damage to the windshield or frame.
3Force
If traditional tools are used to break and pull the windshield out, then the removal force is sufficient, but the time required and potential damage increase
Solution Approach 1:
The patent replaces the traditional mechanical removal process (using scoring and cutting tools to break the adhesive bond) with a thermal-mechanical system. A heating element heats the adhesive to soften it, and a shape memory alloy wire expands in response to the heat, automatically generating the force needed to push the windshield out. This substitution eliminates the need for manual tool operation and reduces removal time while maintaining sufficient removal force.
Solution Approach 2:
The shape memory alloy wire is designed to automatically expand when heated to the trigger temperature, self-generating the removal force without requiring external mechanical intervention. The heating element activates the wire, and the wire's phase transition automatically pushes the windshield out of the frame. This self-service mechanism eliminates the need for operators to manually apply force with tools, significantly reducing removal time and labor.
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
Enables easy and efficient removal of windshields with minimal damage, using a controlled heating process to weaken the adhesive and activate the shape memory wires for forceful disengagement.
Implementation Method 1
the heating element is heated to heat the bonding material and the at least one popwire
Implementation Method 2
the popwire transitions from a martensite phase to an austenite phase. In transitioning to the austenite phase the popwire recovers a remembered shape that generates force
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A system for bonding a windshield to a windshield frame, the system comprising: at least one layer of bonding material that bonds the windshield to the windshield frame; at least one heating element embedded in the bonding material; at least one shape memory element formed from a shape memory material embedded in the at least one layer of bonding material in close proximity to the at least one heating element; at least one electrical power source coupled to the at least one heating element; and a controller operable to control the at least one electrical power source to generate current in the at least one heating element to generate heat that softens and weakens the bonding material and causes the at least one shape memory element to transition to a remembered shape that operates to disrupt the bonding layer and free the windshield from the windshield frame.