Composite Windshield Pane Cutout for Sensor Optical Quality
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Solution Overview
Problem
Modern vehicle windshields face challenges with sensor obstructions, glass breakage during bending, and reduced optical quality due to the need for enlarged masking prints and heating elements, which compromise sensor window stability and clarity.
Innovation Solution
A composite pane design featuring an outer and inner glass pane with thermoplastic intermediate layers and an inlay element, where the inner pane has a cutout that aligns with a cutout in the second thermoplastic intermediate layer, allowing for reduced masking print size and optional electrically conductive heating elements, enhancing stability and optical quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a cutout is made in the inner pane to improve optical quality and reduce masking print size, then the sensor window area is increased and optical clarity is improved, but the mechanical stability of the composite pane is reduced
Solution Approach 1:
The patent uses a composite structure consisting of an outer glass pane, an inner glass pane with a cutout, and a thermoplastic intermediate layer. The thermoplastic layer acts as a flexible connector that maintains mechanical strength while allowing the cutout in the inner pane to improve optical quality. This composite approach resolves the contradiction by combining the benefits of both glass panes and the flexible intermediate layer.
Solution Approach 2:
The patent divides the windshield into separate functional components: an outer pane for structural integrity, an inner pane with a cutout for optical quality, and a thermoplastic intermediate layer for bonding and flexibility. This segmentation allows each component to optimize its specific function without compromising the overall system.
2Object-affected harmful factors
If the masking print is enlarged to obscure sensors on the windshield, then sensor obstructions are covered, but the area available for sensor windows is reduced and optical quality deteriorates
Solution Approach 1:
The patent extracts the masking function from the glass panes and places it in the thermoplastic intermediate layer. This allows the glass panes to maintain their full area for optical quality while the masking print in the intermediate layer provides the necessary obstruction coverage for sensors.
Solution Approach 2:
The patent moves the masking print from the two-dimensional glass surface to the three-dimensional thermoplastic intermediate layer between the panes. This dimensional change allows the masking print to be positioned independently from the glass surfaces, enabling full utilization of glass area for optics while providing sensor obstruction.
3Object-affected harmful factors
If heating wires are laminated into the sensor window region to prevent ice and fog, then anti-icing functionality is improved, but the optical quality of the sensor window deteriorates
Solution Approach 1:
The patent uses the thermoplastic intermediate layer as an intermediary that can contain heating elements without directly contacting the glass panes. This allows heating functionality to be integrated while maintaining optimal optical quality in the sensor window region, as the heating elements can be positioned within the intermediate layer rather than on the glass surfaces.
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 design reduces the risk of glass breakage, improves optical quality, and maintains mechanical stability while allowing for the incorporation of electrically conductive elements, such as heating features, within the sensor window area.
Implementation Method 1
During the bending process, which is usually carried out at temperatures from 500° C. to 700° C., the heat is absorbed more by the screen print than by the respective pane.
Implementation Method 2
The refractive forces in the region of the sensor window are reduced by more than 50% compared to a composite pane in which the inner pane has no cutout in the region of the sensor window.
Data Source
AI summary
A composite pane includes an outer pane and an inner pane which are joined to one another via a first thermoplastic intermediate layer arranged directly adjacent the outer pane and a second thermoplastic intermediate layer arranged directly adjacent the inner pane, and an inlay element which is arranged in a region of the composite pane between the first thermoplastic intermediate layer and the second thermoplastic intermediate layer. The inner pane has a cutout and the second thermoplastic intermediate layer has a cutout. The cutout of the second thermoplastic intermediate layer is, when looked through, arranged completely within the region in which the inlay element is arranged, and the cutout of the inner pane is, when looked through, arranged completely within the cutout of the second thermoplastic intermediate layer.