MXPA97006936A - Apparatus and method for sealing an electrical connection to a lamin transparent sheet - Google Patents

Abstract

The present invention provides an apparatus and method for filling and sealing an opening in a laminate and sealing in particular the notched region of a vehicle windshield. A mold element includes a mold, a reinforcing sheet, a sealant inlet and a vent hole. The mold has a smooth surface to form the surface of the sealant that fills the opening. The mold member is fixed to the laminate in such a manner that selected portions of the mold cover the opening and the remaining portions of the mold coat selected portions of the laminate immediately adjacent the opening. Sealant is injected into a cavity formed by the laminate and the mold member to seal the opening. The sealant is allowed to cure to achieve the desired hardness, and the mold element is removed after the sheet

Description

APPARATUS AND METHOD FOR SEALING AN ELECTRICAL CONNECTION TO A LAMINATED TRANSPARENT SHEET BACKGROUND OF THE INVENTION 1. Field of the invention The present invention relates to the filling and sealing of openings in a laminate, and in particular to an apparatus and method for sealing the electrical connection zone of an antenna formed between the two glass folds. of a laminated transparent sheet. 2. Technical considerations In the past, the traditional motor vehicle antenna for receiving and transmitting electromagnetic signals was an antenna of the whip or mast type. Recently, it has tended towards the incorporation of the antenna in the structure of the vehicle. For example, U.S. Patent 3,987,449 to DeAngelis et al. Discloses a laminated wire antenna within the windshield of the vehicle. U.S. Patent 4,707,700 issued to Nagy places an antenna within the roof structure of a vehicle. U.S. Patent 5,416,491 issued to Nishikawa et al. Forms antenna elements in a window using electroconductive ceramic paints. U.S. Patents 4,768,037 and 4,849,766 issued to Inaba et al. And 5,355,144 to Alton et al. Use a transparent electroconductive coating laminated between two glass folds to form an antenna. U.S. Patent 5,083,135 to Nagy et al. Uses a transparent "T" coating to form an antenna. In each system, the connector assembly conducts the signals received by the antenna to a receiver, for example a radio.

To carry the signals received by the antenna element to a signal receiving device, connectors have been used, such as cables, braided wires or metal tabs. When the antenna is formed from electroconductive elements laminated with a transparent sheet, for example, a windshield, problems arise when said connecting elements are also laminated within the transparent sheet. In particular, it has been found that, by incorporating these types of connectors between the folds of the glass laminate, air may be trapped inside the laminate near the connector. It is considered that the connector hinders the deaeration of the laminate during a conventional operation of preliminary pressing with roller. The bubbles formed by trapped air deteriorate the aesthetic appearance of the window, in addition to increasing the possibility of delamination at or near the connector. To avoid this problem, a notch can be cut along the edge of one of the glass folds to facilitate electrical connection to the antenna elements extending within the notched zone, for example, as described in the Patents of the United States No. 3,987,449 and 4,849,766. In U.S. Patent 5,213,828 to Winter et al., A similar method is described, where electrical connection had to be made with the electrically conductive elements of an electrically heatable windshield. To protect the connection and seal the notched area, the notched area is filled with a sealing material that is typically applied to the notched area and smoothed with a caulking spatula or other similar tool. As an alternative, tape can be used to cover the notched area, and the sealant is injected into the notch below the tape. These sealing procedures are slow and do not provide consistent, reliable results. In particular, it is difficult to guarantee that the notched zone is completely filled. In addition, the exposed surfaces of the sealing material along the main surface of the windshield and along its edge may be irregular. This can pose a problem when applying adhesive around the marginal edge of the windshield before mounting it on a vehicle. It would be advantageous to provide a mounting where the notched area is effectively filled quickly and consis-, and also provide a smooth finish along the surface of the sealant. COMPENDIUM OF THE INVENTION The present invention provides a mold element for filling and sealing an opening in a laminate. The mold element includes a mold, a reinforcing sheet, a sealant inlet and a vent hole. The mold has elastic contact surfaces with sealant that provide a smooth surface to form the surface of the sealant that fills the opening. In the case where the laminate opening is a notched zone formed along the edge of the laminate, in a particular embodiment of the invention, the mold includes a first section having a first elastic contact surface with sealant and a first surface opposite, and a second section that extends generally perpendicular from the first section. The second section has a second elastic contact surface with sealant extending from the first elastic surface of the first section and a second opposing surface. The reinforcing plate covers selected portions of the first and second opposing surfaces. The present invention also discloses a method of sealing an opening in a glass laminate. The laminate includes a first sheet laminated to a second sheet, and the opening extends at least through the first sheet. A mold member having a mold with elastic contact surfaces with sealant is placed in the laminate in such a way that selected portions of the mold cover the opening and the remaining portions of the mold coat selected portions of the laminate immediately adjacent to the opening. . The mold element is fixed to said laminate in such a way that the opening is sealed against the elastic mold surfaces and the mold and the laminate form a closed cavity. Sealant is injected into the cavity to seal the opening and allowed to cure to achieve the desired hardness. The mold element is then removed from the laminate. In the case where the opening is formed along an edge of said first sheet of the laminate, in a particular embodiment of the invention, the mold member is placed along the edge of the laminate in such a way that the first portions of the mold extend along selected portions of a major surface of the laminate immediately adjacent the opening and the second portions of the mold extend along selected portions of the edge of said laminate immediately adjacent the opening. The mold element is fixed to the laminate to keep it in position. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a plan view of a laminated glass antenna with an electrical connection made within a notched zone along one edge of the laminate. Figure 2 is an enlarged plan view of the connection area of the antenna illustrated in Figure 1. Figure 3 is a view taken along line 3-3 of Figure 2. Figure 4 is a view in plan of the mold element of the present invention. Figure 5 is an end view of the mold member taken along line 5-5 of Figure 4. Figure 6 is a view taken along line 6-6 of Figure 5. Figure 7 is a sectional view similar to that shown in Figure 3, taken along line 7-7 of Figure 4, with the mold member positioned in the notched region of the laminate, with portions removed for clarity. Figure 8 is an isometric view of the connector used with the notched zone. Figure 9 is a sectional view similar to Figure 7 of an alternative embodiment of the invention. DETAILED DESCRIPTION OF THE INVENTION The present invention is described in combination with an antenna system for automotive windshields. However, it should be appreciated that the present invention can be used in other applications where an opening or other indented area of a structure has to be filled., and in particular in combination with other types of systems that require electrical connection to conductive elements within a notched zone or other opening in a glass laminate. Figure 1 illustrates a laminated vehicle windshield 12 formed by outer and inner glass folds 14 and 16, respectively, which are joined by an interlayer layer of plastic 18, preferably polyvinyl butyral. The folds 14 and 16 may be of other transparent rigid materials, for example, acrylic, polycarbonate, or the windshield 12 may include a combination of different transparent rigid materials. The windshield 12 further includes at least one antenna element 20. In the particular antenna configuration illustrated in Figure 1, the antenna element 20 is a transparent electroconductive coating applied on the surface 22 of the glass fold 14 in a manner known in the art. material, and generally occupies the central portion of the windshield 12. The coating may be a one or more layer, metal-containing coating, for example, as described in U.S. Patents 3,655,545 to Gillery et al., 3,962 .488 granted to Gillery, and 4,898,789 granted to Finley. It should be appreciated that the antenna element 20 may have a configuration different from that shown in Figure 1. For example, the element 20 may be T-shaped, as represented in U.S. Patent 5,083,135, or may include multiple antenna elements with various shapes that are electrically interconnected directly or indirectly. Although the antenna element 20 explained above is a transparent coating, if the antenna element is not placed in the main viewing area of the windshield 12 or does not obstruct the main viewing area of the transparent sheet of the vehicle, the antenna element 20 it can be of a non-transparent electroconductive material, for example, ceramic paint containing silver, metallic wires, metal foil, etc. In addition, the antenna may include a combination of coating, wire and / or ceramic antenna elements. Still referring to Figure 1, the antenna element 20 of this particular configuration is substantially quadrilateral in shape and is preferably spaced from the peripheral edge of the windshield 12. The exact shape and position of the element 20, as well as the additional antenna elements, it depends in part on the design of the vehicle in which the windshield 12 is installed, the windshield installation angle, the resistivity of the cover, the type of signal to be transmitted or received and the desired performance of the antenna. These types of design considerations for a clear glass antenna are explained in U.S. Patents 4,768,037, 4,849,766 and 5,083,135. With reference to Figures 2 and 3, a connector 24 makes a connection between the antenna element 20 and an electromagnetic energy transmitting and / or receiving device 26 (shown only in Figure 1), and is fixed to the windshield 12, as it will be explained later in more detail. The device 26 can be a radio, cellular phone, television, global position system or any other type of system that uses an antenna element 20 to transmit and / or receive signals. Although not necessary, in the particular antenna assembly shown in Figure 1, the connector 24 is positioned along the upper edge 28 of the windshield 12. The connection assembly between the connector 24 and the antenna element 20 is configured to Such a way that the connector 24 is not laminated between the folds 14 and 16. In this way the problem of trapped air resulting from a laminated connector inside the windshield 12 is eliminated. More specifically, a notched zone 30 of the inside fold 16 is cut to along the upper edge 28 of the windshield 12, as shown in Figures 1-3. In a particular embodiment of the connector assembly, a corresponding section of the interleaved layer 18 is removed from the notch zone 30. The connector 24 is adhered to a portion of the antenna element 20 that enters the notched zone 30, and the notched zone 30 is filled with a sealing material 32. to better fix the connector 24 in position and seal the notched zone 30, as will be explained later in more detail. When the antenna and the configuration of the notched zone are such that a portion of the antenna element 20 passes through the notched zone 30, the connector 24 is fixed directly to the element 20. Alternatively, the antenna element 20 may include a extension 34 that introduces the antenna element 20 into the notched area 30 and provides an assembly whereby the connector 24 can be electrically coupled to the antenna element 20. Although not necessary, the extension 34 can be made of the same material as the element 20. It is preferred that the element 20 or the extension 34 not extend to the edge 28 of the windshield 12 in the notched zone 30, but rather end at least 1 mm from the edge 28 to ensure that the antenna electroconductive elements are completely sealed within the notched zone 30 with sealant 32 to inhibit the degradation of the antenna element along the edge 28. The connector 24 is preferably manufactured in part. r of stainless steel, copper, tin, brass or any other electroconductive material. If necessary, combinations of materials, such as stainless steel or brass coated with copper, tin or silver, can be used to improve conductivity, strength and chemical durability. In the particular embodiment illustrated in Figures 2, 3 and 8, the connector 24 includes a pad section 36 which covers and is in electrical contact with a portion of the extension 34 of the antenna element 20, a section 38 along the length of an edge of the pad 36, and an insulated connector wire 40 that is fixed to the section 38. The section 38 is positioned along an edge of the pad 36 to provide an unobstructed top surface along which it is placed. it can apply pressure to fix the connector 24 to the extension 34. The end 42 of the wire 40 extends within the section 38 and is fixed to it in any convenient way, for example, by crimping the section 38 around the end 42 and / or welding the thread in position. In this connector embodiment, the sections 36 and 38 are formed by a continuous metallic element so as to be integral with each other. The electrical contact made by the section 36 with the extension 34 may be a direct connection or a capacitive connection, as will be explained later in more detail. The connecting wire 40 includes a terminal assembly 44, for example, a male JASO plug, as shown in Figures 2 and 3, or another electrical connection device known in the art, connected to the end 46 of the wire 40 so as to a coaxial cable 48 (represented only in FIG. 1) from the device 26 can easily be attached to the connector 24. The wire 40 is insulated to prevent the connector 24 from contacting the vehicle in which the windshield 12 is installed and adversely affecting the antenna performance. In addition, a nonconductive shrink wrap cover 50 can be applied to the assembly 44 near the end 46 of the wire 40 to further isolate the connector 24 and make it easier to handle the assembly 44. An adhesive 52, shown only in FIGS. and 8, is applied to the section 36 to fix the connector 24 to the antenna element 20 in the outer glass fold 14. As explained above, the electrical connection between the connector 24 and the element 20 can be a direct connection or a capacitive connection. More particularly, the adhesive 52 can be an electrical conductor to provide a direct electrical connection between the connector 24 and the antenna element 20, or it can be non-electrically conductive so that the electrical connection is capacitive. It has been found that a capacitive connection can be used to produce a capacitive reactance that matches the inductive reactance of the antenna to the coaxial cable 48 (shown only in FIG. 1) used to connect the antenna element 20 to the transmitter / receiver device., minimizing the net reactive component as described in U.S. Patent 5,355,144. The necessary surface area of the section 36 of the connector 24 is based, in part, on the spacing between the section 36 and the antenna elements 20, i.e. the thickness of the adhesive, the types of materials used for the antenna element, the connector and the adhesive, and the desired type of connection, that is, direct or capacitive. In cases where there is direct electrical connection between the connector 24 and the element 20, it may be desirable that the surface area provided by the pad section 36 be sufficiently large that, in the event that a conductive adhesive 52 fails, the connector 24 still maintain a capacitive connection that allows continued operation of the antenna element 20. If desired, dyes can be added to the adhesive 52 to hide the connector 24 seen through the outer surface of the windshield 12. Sections 36 and 38 of the connector 24 are preferably made from tinned brass or tinned stainless steel, the base metal thickness ranging from 0.051 to 0.51 mm (0.002 to 0.02 inch), and more preferably ranging from 0.13 to 0.18 mm (0.005 to 0.007 inch). When using non-veneer connectors and in particular stainless steel connectors, it may be necessary to polish the inner surface of the pad section 36 with an abrasive before applying a conductive adhesive 52 to remove the oxide layer and ensure good electrical contact between the connector and the antenna element 20 or the extension 34. The adhesive 52 can be a two-sided tape, powdered adhesive or any other type of adhesive system known in the art. As explained above, the connector 24 is positioned within the notched zone 30 along the edge 28 of the windshield 12. The notched zone 30 must be large enough to accommodate the connector 24, as well as provide for sufficient spacing between the edge 54 of the connector 24 and the edge 28 of the windshield 12, to ensure that the sealant 32 completely covers and seals the connector 24 within the notched zone 30 and provides a continuous barrier to moisture along the edge 28 of the windshield and the edge 56 of the notch. The spacing between the edge 54 of the connector and the edge 28 of the windscreen should be at least 1 mm, preferably at least 3 mm. The notched zone 30 is filled with a non-conductive sealant 32 to further protect and secure the connector 24 in position, seal the portion of the antenna element 20 within the notched zone 30 and seal the exposed edge 56 of the notched zone 30 to form a moisture barrier. Further, it is preferred that the surface 58 of the sealant 32 align with the surface 60 of the inner glass fold 16 to provide a smooth, hard, uninterrupted surface along the marginal edge portion of the interior major surface of the windshield 12. Said smooth surface quality along the sealant 32 in the notched zone 30 is obtained with a mold element, which will be explained later in more detail. While not limiting the present invention, the sealant 32 is preferably a room temperature curable material that can be injected into the notched zone 30 and provide a hard surface when curing, preferably a Shore A hardness of at least about 85. In addition, the sealant 32 should not adversely affect the materials forming the antenna element 20 or the extension 34, so as to electrically isolate the connector 24 from the antenna. Sealants used to fill and seal the notched zone 30 include room temperature curable epoxies, such as Plastilok® 421 epoxy obtainable from BF Goodrich, Adhesives Systems Division, Akron, Ohio, and Scotch-Weld® epoxy DP-110 which can be obtained from 3M Industrial Tape and Specialty Division, St. Paul, Minnesota; both are flexible epoxy sealants in two parts. In the present invention, a mold member is used to enclose the notched zone 30 and to shape the sealant 32 during the filling of the notch and the curing operation. With reference to Figures 4-7, the mold member 62 is fixed along the edge 28 of the windshield 12 covering the notched zone 30 and portions of the glass surface 60, forming a closed cavity 63 to be filled with sealant 32. , as will be explained later. The element 62 includes an elastic mold 64 and a rigid reinforcing sheet 66. The mold 64 is preferably made of a material that does not stick to the sealant 32 and withstands high temperatures of up to 93-177 ° C (200-350 ° F) without adversely affecting the mold, for the reasons that will be explained later. In addition, the surface of the mold 64 covering the windshield 12 and the notched zone 30 should have a smooth finish, which not only results in the full notch having a smooth finish, but also makes it easier to remove the mold element. 62 of the cured sealant. The mold surface 70 should also be elastic, so that it can seal with portions of the surface 60 and adapt to irregularities. However, the mold surface should not be so soft that it loses its shape when the sealant 32 is injected into the cavity 63 through the inlet 74 of the mold 64 to fill the notched zone 30, as will be explained below in more detail . It is preferred that the mold has a Shore A hardness of about 50-70, preferably 55-65. While not limiting the present invention, the mold 64 can be made of Silastic® M RTV rubber that can be obtained from Dow Corning Corp., Midland, MI. Said mold material is a two component silicone rubber which provides a Shore A hardness of about 55-57 and a smooth surface quality. As an alternative to building the entire mold 64 from a single material, it is contemplated that the mold 64 may include a stiffer base material and that the surface of the mold 64 which contacts the windshield 12 and covers the notched zone 30 is made from a Elastic material of the desired hardness. With reference to Figures 4-7, the mold 64 includes a main section 68, with a generally flat surface 70 that covers the notched zone 30 and portions of the glass surface 60, and a lip section 72 with a surface 73 that extends along the edge 28 of the windshield 12 to seal the notched zone 30. The section 68 includes a sealant inlet 74 and vent holes 76. While not limiting the present invention, the inlet 74 includes a chamber 77 that extends partially, but not completely, through section 68. The remaining thickness of the mold portion 68 is split from the chamber 77 to the mold surface 70. When a nozzle (not shown) is introduced into the inlet 74 for injecting sealant 32 in the notched zone 30, the slit 78 is forced open. When the notched area is filled, the nozzle is removed and the slit 78 is closed to maintain the sealant within the notched zone 30 while it cures. In addition, the closed slit 78 provides a smooth surface along the mold surface 70, resulting in a corresponding smooth surface 58 of the notched region. The mold 64 also includes a groove 80 extending from the edge 82 along the mold surface 70. The groove 80 is sized to receive a portion of the wire 40 of the connector 24 during the filling operation of the notched area and keep it along the windshield 12 so that the section 68 of the mold 64 can sit flush with the surface 60 of the glass fold 16. During the filling operation of the notch, sealant flows to the slot 80 by adhering a portion of thread 40 to the surface 60. This assembly reduces the possibility that the connection 24 interferes with a system for mounting and applying adhesive to the windshield (not shown) which applies a thread of adhesive around the marginal edge of the windshield 12 along the surface 60. As an alternative, the depth of the notched area 30 may be increased to move the connector 24 further into the edge 28 of the windshield 12 a distance sufficient for the thread 40 to be spaced from the adhesive that is then applied around the marginal edge portion or periphery of windshield 12 to hold the windshield in position in a vehicle. The reinforcing sheet 66 gives rigidity to the mold member 62 and preserves the shape of the mold during the filling operation of the notch. In addition, the reinforcing plate 66 distributes the applied pressure to selected portions of the mold member 62 when it is fixed to the windshield 12. With reference to Figure 5, the portion 84 of the plate 66 is folded over the lip 72 of the mold 64 for sealing the element 62 against the edge 28 of the windshield and ensuring that the sealant 32 does not escape from the notched zone 30 during the notch filling operation and subsequent curing. In the particular embodiment of the mold member 62 illustrated in Figures 4-6, the sheet 66 also ides tabs 86 which are received within corresponding cavities of the section 68 to hold the mold 64 and the reinforcing sheet 66 together and prevent the Large deflection of the mold 64 when the element 62 is fixed to the windshield 12. The element 62 is fixed to the windshield 12 in any convenient way. While not limiting the invention, in a particular embodiment, the element 62 is fixed to the windshield 12 by applying a force (indicated by the arrow 88 in Figure 7) to the reinforcing plate 66 along a line slightly outward from the notched zone 30 and a corresponding force along the glass fold 14 (indicated by arrow 92 in Figure 7). This latter force is preferably applied by means of a rubber seal 94 or other elastic material so as to distribute the force and prevent the breakage of the glass. The concentration of the forces in said zones guarantees a good hermetic seal between the element 62 and the windshield 12 along the notched zone 30. If desired, the mold element 62 can be fixed to a fixing assembly, for example , with screws or some other type of connector system, so that the element 62 can be placed on the notched zone 30 and fixed to the windshield 12 in a continuous operation. One or more cavities (not shown) can also be provided along the portion of the surface 70 that covers the surface 60 of the glass fold 16 and vacuum can be made through the cavities to further fix the mold element 62 to the windshield 12. The reinforcing plate 66 can be made of any rigid material that distributes the clamping forces along the mold element 62. While not limiting the present invention, in one embodiment, the sheet 66 was an aluminum sheet 2.03 mm (0.080 inch) thick. In a particular configuration of the antenna, the antenna element 20 was a transparent, electroconductive, multi-layered coating, centered on the surface 22 of the glass fold 14 within the main vision zone of the windshield 12 and had a resistivity of about 3 square ohms. The distance from the edge of the antenna element coating to the edge of the windshield 12 varied, with a minimum separation of 6.4 mm (0.25 inch) between the main portion of the coating that forms the antenna element 20 and the metal frame ( not shown) surrounding the windshield 12. An extension 34 was used to bridge the space between the antenna element 20 and the notched zone 30 as shown in figures 1 and 2. Although not precise, it is preferred that the notched area is positioned in the central portion of the windshield 12, that is, within the central third of the windshield 12 and more preferably in the center of the windshield 12. The extension 34 was an identical coating and applied at the same time as the antenna element 20. extension 34 had 254 mm (1 inch) wide to accommodate the entire width of the pad section 36 of the connector 24, which is explained later. In this particular embodiment of the antenna, the edge 90 of the extension 34 was spaced approximately 14 mm (0.55 inch) away from the edge 28 of the windshield to prevent electrical coupling of the metal coating to the undercarriage of the vehicle through the vehicle adhesive. urethane used to fix the windshield 12 to the opening of the vehicle. It is considered that said electrical coupling will adversely affect the performance of the antenna. The notched zone 30 had a depth of approximately 27 mm (1.06 inch) and a width of 150 mm (3.94 inch). The mold portion 68 was about 6,35 cm by 16,51 cm by 1,11 cm (2.5 x 6.5 by 0.438 inch) thick to cover the notched zone 30 and suitably overlap portions of the surface 60 to provide an adequate seal. The lip portion 72 extended down approximately 7.92 mm (0.312 inch) from the portion 68 to seal the edge of the notched zone 30 along the edge 28 of the windshield. If desired, the surface 73 of the leg 72 can be contoured to follow the curvature along the edge 28 of the windshield. Sections 36 and 38 of connector 24 were a tinned brass element approximately 0.178 mm (0.007 inch) thick. Section 36 measured approximately 8 x 20 mm (0.31 x 0.79 inch) and was positioned so that it was completely on extension 34 and there was a minimum of 15 mm (0.59 inch) between edge 54 of the section 36 and edge 28 of windshield 12. Wire 40 was a 20 gauge insulated wire with a JASO pin attached to end 46. Section 36 was attached to extension 34 by a two-sided electrical conductive adhesive tape. about 0.051 mm (0.002 inch) thick, for example, tape number CD-9082, which can be obtained from Specialty Tapes, Wl, to make a direct electrical connection. Alternatively, an electrical non-conductive adhesive, for example product number 9482, obtainable from 3M Company, may be used to secure the section 36 to the extension 34 (or the element 20) to form a capacitive connection. The notched zone 30 was filled with Scotch-Weld epoxy DP-110. This particular sealant was modified by the addition of silane, for example, Dow Corning® Z-6040 silane, which can be obtained from Dow Corning, Midland, Michigan, to the epoxy resin component in an amount equal to about 0.2-8. % by weight of the resin, and preferably 0.5-2% by weight, to improve the bonding of the sealant to the glass. In addition, carbon black, for example Arospere ™ 11V carbon black, which can be obtained from JM Huber Corporation, Borger, Texas, was added to "hide" the full notch giving a black appearance consistent with the black ceramic rim (not shown). which is typically applied around the marginal edge portion of the windshield of a motor vehicle. In this particular embodiment, the carbon black was added to the accelerator component in an amount equal to about 1-1.5% by weight of the accelerator. The sealant was applied using a static mixing applicator that mixed equal amounts of the epoxy in two parts immediately before its injection into the notched zone 30. Once applied, the sealant sets in about 15 minutes, so that it can be handled more easily. Once completely cured, the epoxy has a Shore A hardness of about 88. Alternatively, W041696 Tl Black, which is a two-part structural adhesive obtainable from Advanced Polymer Concepts, Germantown, Wi. The latter material provides a Shore A hardness of about 95. In manufacturing the windshield 12 described above, the transparent electroconductive coating was applied to the glass ply 14 in a manner known in the art, using a mask to obtain the desired antenna configuration. Alternatively, the entire surface 22 of the fold 14 can be coated and then selected portions of the coating removed to obtain the desired antenna configuration. After the coating, the fold 14 was combined with the fold 16, which includes the notched area corresponding to the notched zone 30, and the two folds were formed simultaneously using techniques known in the art, for example, buckling by gravity. If desired, the folds 14 and 16 can be formed separately and / or before applying the antenna element 20. After forming, the interleaved layer 18 was inserted between the folds 14 and 16 with a notched section in the layer intercalated corresponding to notched zone 30. The whole was then deaerated and laminated using techniques known in the art., to form a unitary structure. After the lamination, the notched zone 30 was cleaned and the pad section 36 of the connector 24 was fixed to the extension 34. The mold member 62 was then placed over the notched zone 30, the yarn 40 extending from the mold 64 to through slot 80 and fixed in position. The sealant 32 was then injected into the notched zone 30 through the inlet 74 of the mold 64. After filling, the sealant 32 was allowed to cure and cure for approximately 20 minutes to achieve the desired surface hardness before removing the mold 62. It is noted that the curing time of the sealant can be reduced by heating the mold member 62 and / or heating the notched zone 30 before, during and / or after filling at a temperature of about 73-177 ° C ( 200-350 ° F). For this reason, if heating is used to accelerate the cure, the mold material must be able to withstand such high temperatures. In addition, the sealant 32 can be heated during the filling operation of the notch to decrease its viscosity and reduce its curing time. Care must be taken when heating the sealant to ensure that it does not become hot at too high a temperature, resulting in chemical decomposition of the sealant. Although the above-explained invention included only an electrical connection to the antenna element 20, it should be appreciated that multiple connections can be made to the antenna element 20 along one or more edges of the windshield 12 in a manner similar to that described herein. memory. As described herein, the mold member 62 is used to seal an electrical connection made in a notched zone 30 positioned along an edge of the windshield 12. However, the ideas of the present invention can also be Use to seal a connection made in a windshield opening separated from its edge. More specifically, with reference to Figure 9, the glass fold 116 includes within its periphery a hole 130 located so as to cover the electroconductive extension 134 in the glass fold 114 of the windscreen 112. A corresponding hole 110 is formed in the interleaved layer 118. A connector 124 is placed within the hole 130 and fixed to the extension 134. A mold member 162 can be fixed with an elastic mold 164 and a reinforcing sheet 166, similar to that described above, to the windscreen 12 of any convenient way to cover the hole 130. Sealant (not shown) could then be injected through the mold member 162 to seal the hole 130 and better secure the connector 124 in position. The invention described and illustrated herein represents a description of its illustrative preferred embodiments. It is understood that several changes can be made without departing from the essential idea of the invention defined in the following claims.

Claims (19)

1. CLAIMS 1. A mold element for filling an opening in a laminate and forming sealant used to fill said opening, including: a mold with an elastic contact surface with sealant and an opposite surface; at least one sealant inlet; at least one ventilation hole; and a reinforcing sheet fixed to said mold and coating selected portions of said opposite surface.
2. 2. The mold element according to claim 1, wherein said elastic surfaces of said mold have a Shore A hardness of about 50 to 70. The mold element according to claim 2, wherein said elastic surfaces of said mold have a Shore A hardness. from about 55 to 65. The mold element according to claim 3, wherein said mold is made of silicone rubber. The mold element according to claim 1, wherein said first elastic surface includes a slot sized to receive an electroconductive element extending from within said opening. The mold element according to claim 1, wherein said inlet and the vent hole extend through said first section of said mold. The mold element according to claim 1, further including means for securing said mold element to said laminate. The mold element according to claim 7, wherein said fixing means includes means for applying pressure to selected portions of said reinforcing plate to compress said mold and attaching said mold element to said laminate. The mold element according to claim 1, wherein said elastic contact surface with sealant is a first elastic contact surface with sealant of a first section of said mold, and said opposite surface is a first opposite surface of said first portion, and said mold further includes a second section extending generally perpendicular from said first section, said second section having a second elastic contact surface with sealant extending from said first elastic surface and a second opposing surface, wherein said reinforcing plate covers selected portions of said first and second opposed surfaces. The mold element according to claim 9, wherein said mold is made of silicone rubber, said elastic surfaces having a Shore A hardness of about 50 to 70, said inlet and the vent hole extending through said first section of said mold, and means for fixing said mold element to said laminate. 11. A method of sealing an opening in a glass laminate, said laminate having a first sheet, said opening extending therethrough, and a second laminated sheet to said first sheet, including the steps of: placing a mold element having a mold with elastic contact surfaces with sealant on said laminate so that selected portions of said mold cover said opening and the remaining portions of said mold coat selected portions of said laminate immediately adjacent said opening, wherein said mold and laminate form a cavity between them; fixing said mold element to said laminate in such a way that said opening is sealed against said elastic mold surfaces; injecting a sealing material into said cavity to seal said opening; let said sealant cure and achieve a desired hardness; and removing said mold element from said laminate. The method according to claim 11, wherein said fixing step includes the step of applying a force to selected portions of said mold that cover said first sheet to push said mold against said laminate and compress said selected portions of said mold in such a way that hold said mold in position. The method according to claim 12, wherein said fixing step includes the step of fixing said mold element to said laminate. 14. The method according to claim 11, further including the step of heating said sealant before said injection step to accelerate said curing of said sealant. The method according to claim 11, further including the step of heating said mold prior to said laying step to accelerate said curing of said sealant. The method according to claim 11, further comprising the step of heating said mold and sealant after said injection step to accelerate said curing of said sealant. The method according to claim 11, further comprising the step of fixing an electrical connector within said opening before said laying step. The method according to claim 11, wherein said opening is formed along an edge of said first sheet and said placing step includes the step of placing said elastic mold on said opening such that first portions of said mold are extend along selected portions of a major surface of said laminate immediately adjacent said opening, and second portions of said mold extend along selected portions of an edge of said laminate immediately adjacent said opening, wherein said mold and laminate form said closed cavity between them. The method according to claim 18, wherein said fixing step includes the step of fixing said mold element to said laminate.