CN110573343A - 带嵌入式电路的汽车夹层玻璃 - Google Patents
带嵌入式电路的汽车夹层玻璃 Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
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- H—ELECTRICITY
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- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
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Abstract
带有嵌入式电路的夹层玻璃有多种用途。但是,由于制造成本较高,它们并没有得到广泛的应用。本发明提供了一种能够降低嵌线夹层玻璃加工成本的工艺。不是一次在一张中间层片材上嵌入电线,而是在同一张片材上加工多个电路,在组装过程中将其切断,然后***到每个单独的层压玻璃中间层中,减少了所需的直接人工和资本性投资。
Description
发明领域
本发明涉及一种成本较低的带有嵌入式电路的汽车夹层玻璃以及用于制造所述玻璃的方法。
背景技术
带嵌入式电路的夹层玻璃有多种用途,包括但不限于除霜、射频接收、电容式雨水感应、乘坐者感应、触摸控制、照明、数据传输、RFID(射频识别)、控制信号和电源。所述功能的平面电路设计是已知技术,而嵌入式电路设计图纸极易传播,毫不费工夫,或是可以由那些只有普通技术的人来完成。
然而,由于其制造成本较高,除了除霜外,嵌入式电路还没有得到广泛的应用。讨论的重点应放在除霜上,但该工艺可应用于任何其他使用嵌入式线路的应用。
汽车车窗通常都装有电加热电路,以便通过加热玻璃来保持视野清晰,从而免受冰、雪和雾的困扰。在大多数车型上,后车窗除雾器曾是一种选装配置,但从多年前开始就已成为标准配置了。
大多数后车窗都是由钢化防护玻璃制成的。钢化防护玻璃是通过热处理工艺加强玻璃强度而制成的一种玻璃。钢化防护玻璃破碎时会碎成带钝边的小颗粒。
从另一方面来说,挡风玻璃是由两层退火玻璃制成的,这两层玻璃由一层薄薄的塑料中间层固定在一起。中间层通常是透明的热塑性材料。对于汽车来说,最常用的中间层材料是聚乙烯醇缩丁醛(PVB)树脂。除了聚乙烯醇缩丁醛外,还可使用离子性聚合物、聚氨酯(PU)和乙烯醋酸乙烯酯(EVA)。挡风玻璃破碎时,玻璃破碎成大片危险的尖锐碎片,但塑料中间层会将玻璃碎片粘在一起,有助于保持玻璃的结构完整性。
由于钢化玻璃仅由单层玻璃构成,加热电路只能应用于车辆内部的玻璃一侧。这些电路通常为丝网印刷电路,用含有银粉和细玻璃粉的油墨涂在平直玻璃上。当玻璃被加热到可以弯曲的程度时,油墨被“烧制”到玻璃表面。也就是说,油墨中的玻璃粉达到了其软化点,并与玻璃表面熔合。而银具有导电性,可在玻璃上加工成各种印刷电路。典型的12伏后车窗除霜器有一个丝网印刷电路,银墨中银的重量百分比在65%到75%之间,线宽在0.3毫米到0.8毫米之间,线间距在30毫米到35毫米之间。由于乘车者有可能接触到玻璃上的除霜器线路,因此功率受到限制,升温不超过40至45℃。电路也会通过一个定时器进行控制,这样就不会因为长时间加热而过热。
在挡风玻璃上,丝网印刷银墨只能在玻璃的限定区域使用。否则,这些线会分散驾驶员的注意力,干扰其视线。
一些车型的挡风玻璃雨刮器在静止时停在发动机罩边线的下方位置。这样做的目的是减少风噪音和风阻。此类车辆中的大部分必须配备雨刮器区域加热除霜器(HWA8),如图1A和1B所示,以融化可能积在那里的冰和雪。HWA 8电路需要比后车窗更高的功率密度,因为可能会有大量的冰积在那里。
对于那些在挡风玻璃上装有摄像头的车辆,则需要一个除霜电路来保持该区域的清晰度。来自除霜器的热空气不会影响到该区域,因为它被摄像头10所阻挡;并且由于玻璃的热传导能力较低,仅仅通过传导,该区域在合理的时间内是不会变清晰的。此外,虽然后车窗除雾器的一般除雾规格是在-20摄氏度的环境温度以及冰厚度为0.5毫米的情况下在20分钟后清除80%,但使用摄像头执行安全功能的车辆通常需要至少两倍的除雾时间,以便启用基于摄像头的安全功能,如车道偏离和前部碰撞警示***。对于无需挡风玻璃清洁即可开始工作的自动驾驶汽车来说更是如此。
虽然银墨丝印除霜器已应用于HWA 8和摄像头10的除霜器,但是更高的功率密度要求让设计更具挑战性。如前所述,典型的后车窗除雾器的功率密度为每平方分米4到6瓦。然而,HWA 8和摄像头10的电路在每平方分米10到15瓦的范围内工作。在HWA 8除霜器上,线宽往往在2毫米至6毫米之间。银的价格很高并且会使玻璃弱化。在摄像头除霜器10上,线宽则往往是尽可能窄的最小宽度,即0.3毫米至0.6毫米,这就给打印带来了挑战。此外,银线的间距不能超过30毫米至35毫米,因此有时必须穿过摄像头的视野,这是不可取的。
嵌入式电线加热是一个替代银墨丝网印刷的非常好的方法,如图1A和1B所示。除霜器电路是通过将电线5嵌入用于将夹层玻璃的两层玻璃彼此粘合的塑料片或中间层4中加工而成的(图2A)。这就限制了这种技术在夹层玻璃上的应用。对于挡风玻璃来说,12伏的电路是通过在塑料层中嵌入20微米或直径更小的钨丝制成的。在表示摄像头10区域的图2B中,电线沿着该区域左右两侧的垂直母线12的水平方向敷设。在中空挡风玻璃中,电线通常沿着挡风玻璃顶部和底部的水平母线的垂直方向敷设。母线被玻璃的第四和第二表面上的黑漆所遮盖。第四表面是车辆内部的玻璃表面,第二表面是外部玻璃层的内部表面。虽然较短的起步时间是可行的,但功率密度受车辆电气***可用功率的限制,因此通常与后车窗处于相同的范围内。
除了可以使用非常细的电线外,嵌入式电线除霜器电路还有另外一个优点,即比银墨丝网印刷电路加热更加均匀。玻璃的热传导能力很低。银线间距为35毫米时,线与线之间的温差很大。在稳定状态下,在距银线17.5毫米、温度为65摄氏度的情况下,温度可能只有45摄氏度。而具有相同功率密度的嵌入式电路在线间距为4毫米-8毫米的情况下,温差将小于10摄氏度,也有可能低于5摄氏度,且峰值温度将相应降低。由于电线更靠近玻璃的外表面,因此外表面的温度也会高出1-2摄氏度。这样,电路中的能量就会被更有效地利用。事实上,在相同的平均功率密度下,嵌入式电路比银墨丝网印刷电路的除冰速度更快。
基于这些优势,我们期待看到更多的车辆使用嵌入式电路除霜器。我们并没有看到很多车辆装有嵌入式电路除霜器,主要是因为嵌入式电路的成本较高。主要的成本发生因素是劳动密集型工艺和所需的高资本性投资。
在夹层玻璃的塑料中间层中嵌入电线需要一台高精度的计算机数控(CNC)机床。除了X轴和Y轴外,机头还必须能够在Z轴上下移动,并且能够旋转,以便能够沿着刀具路径移动。此外,一个自动换刀器、一个焊接工具和一个电线切断工具以及一个切割工具也是非常有必要的。这种复杂性增加了机床的价格。
机床床身必须足够大,以容纳将要制造的最大尺寸的挡风玻璃。而挡风玻璃的尺寸越来越大。一些汽车的全景挡风玻璃的面积超过了2平方米,而卡车和公共汽车的挡风玻璃面积可高达4平方米,这是众所周知并且是常见的。
但只有少数的几家公司可以生产嵌线机。因此,设备往往价格很高。市场上销售的大部分机床都用于在射频识别卡上嵌入环状天线并且工作包络面小于1米x 1米。大块的汽车挡风玻璃可能需要一个3到4倍大的工作包络面。
所谓的电线应包括但不限于圆形、实心、未绝缘铜电线和/或钨丝。也可以包括其他导电材料以及绞合和绝缘电线。导体的形状也可以是矩形的。典型的钨丝直径范围从最小的约9微米到125微米左右不等。铜线的直径范围可以从大约20微米到250微米左右不等。
加工过程从放置在计算机数控(CNC)嵌线机床床身上的塑料中间层片材开始。首先是敷设母线。母线由很薄的镀锡铜条制成。如有需要,这部分操作可以手工完成,如配有设备,也可以用机器完成。然后,通过加热或超声波将电线嵌入。进给速度是有限的,因为当电线从线轴上放出或者从中间层中将嵌入的线拉出时,机头的速度不能在极细的电线上施加过大的张力。
重要的是,在添加电线和母线时不要拉伸中间层或令其起皱,防止分层和造成光学缺陷。鉴于母线和电线的厚度和硬度,必须将中间层4切成薄片进行加工。不可进行卷对卷加工。即使是薄片,嵌入电线和母线的薄片通常也不能堆叠超过10-20张。
嵌线机的操作必须在花费高昂的无尘室内进行,以防层压材料受到污染。由于典型的汽车玻璃中间层4的玻璃转化点为20摄氏度,因此无尘室的温度也必须保持在15摄氏度左右。一台机床的生产能力取决于嵌入的形状,但要跟上一个高产程序,则可能需要多台大型机床。
例如,一块面积为1.5平方米的挡风玻璃所需的中间层尺寸大于工作包络面为1米x 1米的机床。这一范围内的小型机床在市场上有售,但主要针对的是电子行业。将工作包络面的尺寸从一平方米增加到两平方米,机床的价格通常要高出一倍以上,因为仍需达到同样的精度。然而,根据部件的水平和垂直尺寸,即使是2平方米的包络面也可能不够。挡风玻璃很少有正方形或长方形的,通常是梯形的。假设我们的部件尺寸为1.4米x 1.1米,这是我们确定的最小尺寸。但是为了能够容纳其他较大的部件,将机床尺寸调整到预期的最大尺寸是有道理的,例如2米x 1.5米。
在为HWA 8和摄像头10设计嵌入式加热电路时所面临的问题之一来自于两者的尺寸差异。HWA 8电路的尺寸可以是摄像头10区域电路的几倍。虽然两者的功率密度可能相同,但由于HWA 8的电流较高,因此在两个电路中使用相同的电线是不实际的。如果在同一部件上既有HWA 8又有摄像头10,则嵌线机必须有第二个嵌入工具或必须手动更换工具。这也增加了生产这种电路的成本。
因此,生产嵌入式电路的成本是银墨丝网印刷电路的几倍。
发明内容
了解了银墨丝网印刷和嵌入式除霜器电路的缺点之后,可以理解的是,最好能够生产出一种没有所述限制的除霜器。
主要的成本发生因素是传统工艺的生产能力很低,使用这种工艺每次只能加工一整张中间层片材。
现在是要将多个电路嵌入在一张中间层片材上,而不是每次只为一块挡风玻璃加工一张中间层片材,嵌入一个电路。这就允许使用尺寸更小的中间层片材以及小型且价格并不昂贵的机床。示例如图3、4和5所示。然后,将除霜器电路从片材上切下,这也减少了所需的存储空间。再根据图6A和6B中所示的电路尺寸在夹层玻璃的中间层片材上开口。
组装层压玻璃时,将带电路的中间层片材***切口。通过精确地切割中间层和电路可以达到尺寸完全匹配,并且在实际使用中看不到成品层压玻璃上的切割痕迹。根据玻璃弯曲和电路的形状,可能需要通过粘接来固定电路。如有需要,可通过热(来自含铁)或溶剂(酒精或增塑剂)来粘接中间层,该中间层上的电路已如图7A和7B所示嵌入。
然后,将组装件放置在高压釜中,在高压釜中加热和加压,电路被永久固定在层压玻璃上。当要求使用高质量、价格昂贵的中间层,并且需要嵌入HWA时,整个中间层片材的底层可以使用较便宜的普通中间层,如图5、6A和7A所示。
这样做的好处是:
·成本更低
·生产能力更高
·存储需求降低
·允许使用小型、价格更便宜的机床。
·减少所需机床的台数。
·降低劳动力需求。
·减少资本性投资。
·节省空间。
·减少更换工具的次数。
·减少所需的价格昂贵的中间层(楔形、阳光控制、消音等)材料。
附图说明
通过结合附图对以下实施例的详细描述,进一步说明本发明的特征和有益效果,附图列示如下:
图1A显示的是带有嵌入式摄像头区域和HWA除霜器的夹层挡风玻璃。
图1B显示的是图1A所示挡风玻璃带有嵌入式摄像头区域和HWA除霜器的中间层。
图2A显示的是摄像头区域除霜器电路的横截面。
图2B显示的是摄像头区域除霜器电路。
图3显示的是带有多个摄像头除霜器电路的中间层片材。
图4显示的是带有多个摄像头HWA电路的中间层片材。
图5显示的是带有多个摄像头HWA电路的中间层片材。
图6A显示的是带有切口的中间层,为的是嵌入图1所示的挡风玻璃摄像头区域和HWA除霜器。
图6B显示的是带有切口的中间层,为的是嵌入图1所示的挡风玻璃摄像头区域和HWA除霜器。
图7A显示的是已嵌入图1所示的挡风玻璃摄像头区域和HWA除霜器的中间层。图7B显示的是已嵌入图1所示的挡风玻璃摄像头区域和HWA除霜器的中间层。
参考标号
2 玻璃
4 中间层
5 电线
8 雨刮器区域加热除霜器
10 摄像头除霜器
12 母线
14 切下的电路
具体实施方式
传统嵌线工艺的成本动因是较低的生产能力,并因此造成了资本性投资高、占用空间大并需要较多的劳动力。
在加热挡风玻璃的情况下,几乎所有的表面区域都必须嵌入电线,这要消耗几百米的电线,一次加工一条是使用XY型机床加工电路的唯一方法。计算机数控机床可以加工多条全挡风玻璃电路,其作业方式类似于车床。中间层卷在一个直径为1.5米的大卷筒上,在卷筒旋转时在中间层上敷设母线,并嵌入电线。这种方式适用于这些类型的电路,但不能用于加工摄像头和HWA所需的更复杂的电路。
在同时有摄像头和HWA的挡风玻璃上,总加热面积小于挡风玻璃表面面积的10%。摄像头的面积在1至2平方分米范围内或小于面积为1.5平方米的典型挡风玻璃的2%。这样只需2-4米的电线。HWA的面积更大,但仍然只需要覆盖从雨刮器正下方到热风机***加热的区域。面积大的HWA将在5-10平方分米或表面面积的3.5-7%范围内,只需使用10–20米的电线。
图1A显示的是既有摄像头10除霜器又有HWA8除霜器的挡风玻璃。图1B显示的是在层压之前使用先前技术加工的带嵌入式电路的中间层。注意,黑漆会覆盖并隐藏每个电路上的母线。
当加工带有摄像头10和/或HWA8电路的中间层时,一次加工一片,高达90%的循环时间都用在将中间层片材4放置在机床上并定位,然后在嵌线后移除并堆叠。部分原因是中间层4的尺寸大、材质松软,使其难以处理。
如果HWA8和摄像头10除霜器两个均为必须,则必须更换工具。由于两个电路的尺寸不同,它们几乎无法使用同一种电线,有时甚至不能使用同一种母线。
通过在单张的中间层片材上加工多个相同的电路,然后在进入高压釜之前组装层压玻璃时将电路与较大的片材组合在一起,这样的话劣势就大大减少了。这种方法还可以使用床身较小的机床,价格也较便宜。
需要指出的是,嵌入式电路有多种功能,类型如下:电阻加热电路、天线电路、雨水感应电路、供电电路、乘坐者感应电路、数据传输电路、触摸感应电路、照明电路,控制信号电路等。
实施案例说明
参考图1A,在本发明的一个实施案例中,一块面积为1.4米x 1.2米的挡风玻璃有一个摄像头10除霜器,由两根3毫米x 100毫米的母线和3米长、直径为45微米的钨丝组成,此外还有一个HWA8,由两根6毫米x 100毫米的母线和18米长、直径为80微米的铜线组成。为了满足对夹层玻璃的需求,加工此部件的一条生产线以平均每60秒1次的速度每天运行24小时,每周运行7天,每月运行两周。
包络面至少为1.4米x 1.2米的机床一次处理一张片材,每小时可加工16张中间层片材,如表1所示。因此,需要四台机床,并且使用率必须在96%才能满足需求。
在一张面积为1平方米的中间层片材上可以嵌入60个摄像头10除霜器电路,耗时1522秒,速率为每小时142个(见表2和图3)。在一张面积为1平方米的中间层片材上可以嵌入10个HWA8电路(图4),可以每小时70个的速度进行加工(表3)。这样的话需要两台包络面为1米x 1米的机床,且使用率必须达到64%。将电路14从中间层4片材上切下,然后***单独的层压玻璃中间层片材上专门为电路切好的开口中。然后,将装配好的层压玻璃放在高压釜中进行加热和加压处理,这与标准层压玻璃的加工方式相同。
使用包络面为1米x 1.2米的大型机床时,可以生产HWA8以及整个中间层4的底层,然后在组装时粘接到较短的中间层片材上。当需要更高性能的中间层4(楔形、阳光控制、消音等)时,这是有利的。在被黑漆遮盖的层压玻璃区域中对中间层4的性能没有要求,并且粘接也会被遮盖。
一张1米x 1.2米的中间层片材4上可加工八个HWA电路,如图5所示。其加工速率可达每小时66个(表4)。两台机床的使用率必须达到67%。
在这两种情况下,通过使用两台小型机床替代四台大型机床可以减少资本性投资。使用较少台数的小型机床可以减少占地面积,从而节省无尘室内的空间,同时也能节省加工嵌线中间层所需的存储空间。在组装过程中,需要一名额外的工作人员来粘接中间层,但额外的劳动力可被嵌线过程中劳动力的减少所抵消。
Claims (9)
1.一种制造带嵌入式电路的夹层挡风玻璃的工艺包括以下步骤:
将多个电路的导线嵌入到一张中间层片材上;
将所述电路从所述片材上切下;
在单独的层压玻璃中间层上开口;
将所述电路***所述单独的层压玻璃中间层的切口中;及
并对所述的层压玻璃进行加热和加压。
2.据权利要求1所述的工艺包括将所述电路粘接到所述单独的层压玻璃的步骤。
3.据权利要求1所述的工艺,其特征在于,所述电路选自电阻加热电路、天线电路、雨水感应电路、供电电路、乘坐者感应电路、数据传输电路、触摸感应电路、照明电路和控制信号电路。
4.据权利要求1所述的工艺,其特征在于,所述电路包括直径范围从约9微米到125微米左右不等的钨丝。
5.据权利要求1所述的工艺,其特征在于,所述电路包括直径范围从约9微米到75微米左右不等的钨丝。
6.据权利要求1所述的工艺,其特征在于,所述电路包括直径范围从约20微米到250微米左右不等的铜线。
7.一种夹层玻璃至少包括一种通过据权利要求1所述工艺加工而成的电路。
8.据权利要求7所述的夹层玻璃包括PVB中间层。
9.一种包括权利要求7所述夹层玻璃的车辆。
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Application Number | Priority Date | Filing Date | Title |
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US201762479295P | 2017-03-30 | 2017-03-30 | |
US62/479,295 | 2017-03-30 | ||
CONC2017/0007456 | 2017-07-27 | ||
CONC2017/0007456A CO2017007456A1 (es) | 2017-03-30 | 2017-07-27 | Proceso para la fabricación de laminado automotriz con circuito de alambres integrado |
PCT/IB2018/052154 WO2018185619A2 (en) | 2017-03-30 | 2018-03-28 | Automotive laminate with embedded wire circuit |
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CN110573343A true CN110573343A (zh) | 2019-12-13 |
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US (1) | US11541650B2 (zh) |
EP (1) | EP3600891A2 (zh) |
CN (1) | CN110573343A (zh) |
CO (1) | CO2017007456A1 (zh) |
WO (1) | WO2018185619A2 (zh) |
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EP3264241A1 (en) * | 2016-06-29 | 2018-01-03 | Saint-Gobain Glass France | Lighting laminated glazing with a capacitive touch sensitive device and a light emitting diode and the manufacturing |
CO2018006032A1 (es) * | 2018-03-20 | 2018-07-19 | Agp America Sa | Laminado automotriz con sistema de desempañamiento en el área de la cámara con baja distorsión |
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CN1668461A (zh) * | 2002-07-19 | 2005-09-14 | 皮尔金顿公共有限公司 | 层压玻璃窗板 |
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Also Published As
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US11541650B2 (en) | 2023-01-03 |
CO2017007456A1 (es) | 2018-01-31 |
US20200338866A1 (en) | 2020-10-29 |
WO2018185619A2 (en) | 2018-10-11 |
EP3600891A2 (en) | 2020-02-05 |
WO2018185619A3 (en) | 2018-11-22 |
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