Composite Windshield Inlay for Clear Sensor Windows and Heating
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Solution Overview
Problem
Modern vehicles with increasing numbers of sensors on windshields face challenges such as glass breakage during bending, optical distortions, and reduced optical quality due to conventional sensor window coverings, which also complicate the integration of heating elements and antennas.
Innovation Solution
A composite pane design featuring a thermoplastic intermediate layer and a functional insert element with a carrier layer and electrically conductive elements, allowing for reduced glass breakage, improved optical quality, and integrated sensors, heating elements, and antennas in a single work step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If sensors are mounted on the windshield with horizontal detection direction, then the sensor functionality is achieved, but the sensor window area becomes large and occupies significant windshield surface
Solution Approach 1:
The patent tilts the sensor at an angle relative to the windshield normal, changing the detection geometry dynamically. This angular adjustment reduces the projected sensor window area on the windshield while maintaining detection capability, transforming the static horizontal mounting into a dynamic angular configuration.
2Ease of manufacture
If screen printing is applied to the windshield before bending, then UV protection and aesthetic coverage are achieved, but optical distortions and glass breakage occur during the bending process
Solution Approach 1:
The patent applies the screen print UV protection layer after the bending process rather than before. This reverses the conventional sequence, performing the printing action after the glass has already been shaped, thereby avoiding the harmful interaction between the printing process and the bending thermal stress.
Solution Approach 2:
The patent inverts the conventional manufacturing sequence by applying the screen print layer after bending instead of before. This reversal eliminates the causal relationship between screen printing and subsequent glass breakage or optical distortions during bending.
3Object-affected harmful factors
If heating wires are laminated into the sensor window area, then ice and condensation are prevented, but the optical quality of the sensor window deteriorates
Solution Approach 1:
The patent extracts the heating function from the optical path area by placing heating wires in the peripheral regions surrounding the sensor window rather than within it. This separation removes the harmful visual impact of heating wires from the sensor's field of view while maintaining the anti-icing function through thermal conduction through the glass.
4Adaptability or versatility
If multiple functional elements are applied individually to the windshield, then each element can be optimized, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple functional elements (sensors, heating wires, antennas, screen print layers) into a single integrated windshield structure. All elements are applied simultaneously or in an optimized sequence during one manufacturing process, merging separate operations into a unified production flow that reduces complexity while maintaining individual element functionality.
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 reduces the risk of glass breakage during bending, enhances the optical quality of sensor windows, and simplifies the integration of multiple functional elements, leading to cost and time savings in production.
Implementation Method 1
at least a first disc (2, 3) and a second disc (3, 2) which are connected to each other via at least one thermoplastic intermediate layer (4)
Implementation Method 2
a functional insert element (5) which comprises a carrier layer (6) and at least one electrically conductive element (10)
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The present invention relates to a composite pane (1), at least comprising a first pane (2) and a second pane (3), which are joined together by at least one thermoplastic intermediate layer (4), and a functional inlay element (5), which is provided between the first pane (2) and the second pane (3). The functional inlay element (5) comprises a base layer (6) and at least one electrically conductive element (10).