GLASS PLATE MODULE AND PRODUCTION METHOD FOR GLASS PLATE MODULE
20210410235 · 2021-12-30
Assignee
Inventors
Cpc classification
H05B3/84
ELECTRICITY
C03C27/10
CHEMISTRY; METALLURGY
B60J1/008
PERFORMING OPERATIONS; TRANSPORTING
International classification
H05B3/84
ELECTRICITY
Abstract
A glass plate module according to the present invention includes: a first glass plate having an edge portion on which a notch is formed; a second glass plate that is arranged opposing the first glass plate; an interlayer that is arranged between the first glass plate and the second glass plate; at least one conductive pattern that is arranged between the first glass plate and the second glass plate; at least one conductive cable that is connected to an end portion of the conductive pattern on an exposed surface that is exposed from the notch of the first glass plate on the second glass plate; a restriction member that engages with a portion of the conductive cable and restricts the conductive cable from separating from the exposed surface; and a sealing material that covers at least a connection portion at which the conductive cable and the conductive pattern are connected on the exposed surface.
Claims
1. A glass plate module comprising: a first glass plate having an edge portion on which a notch is formed; a second glass plate that is arranged opposing the first glass plate; an interlayer that is arranged between the first glass plate and the second glass plate; at least one conductive pattern that is arranged between the first glass plate and the second glass plate; at least one conductive cable that is connected to the conductive pattern on an exposed surface that is exposed from the notch of the first glass plate on the second glass plate; a restriction member that engages with a portion of the conductive cable and restricts the conductive cable from separating from the exposed surface; and a sealing material that covers at least a connection portion at which the conductive cable and the conductive pattern are connected on the exposed surface.
2. The glass plate module according to claim 1, wherein the conductive cable is fixed by the sealing material on the exposed surface.
3. The glass plate module according to claim 1, further comprising a spacer that is fixed to the exposed surface and is arranged along an edge portion of the second glass plate, wherein on the exposed surface, the sealing material fills a region surrounded by the spacer and an end surface that extends along the notch of the first glass plate.
4. The glass plate module according to claim 3, wherein the conductive cable is configured to extend toward the spacer past a step between the exposed surface and the spacer.
5. The glass plate module according to claim 3, wherein the restriction member is attached to the spacer.
6. The glass plate module according to any claim 1, wherein the restriction member includes an engagement portion, the engagement portion includes a first end portion and a second end portion, and is formed such that at least one of the first end portion and the second end portion opposes the exposed surface, and the engagement portion is configured to come into contact with an outer peripheral surface of the conductive cable between the first end portion and the second end portion.
7. The glass plate module according to claim 6, wherein the engagement portion is formed into a U shape such that both the first end portion and the second end portion oppose the exposed surface.
8. The glass plate module according to claim 1, wherein the conductive pattern and the conductive cable are electrically connected to each other using lead-free solder.
9. A method for manufacturing a glass plate module, the method comprising: a step of preparing a glass assembly, which includes a first glass plate having an edge portion on which a notch is formed, a second glass plate that is arranged opposing the first glass plate, an interlayer that is arranged between the first glass plate and the second glass plate, and at least one conductive pattern that is arranged between the first glass plate and the second glass plate, an exposed surface that is exposed from the notch of the first glass plate being formed on the second glass plate; a step of electrically connecting a conductive cable to each conductive pattern on the exposed surface; a step of attaching a restriction member that restricts the conductive cable from separating from the exposed surface to a portion of the conductive cable; and a step of arranging a sealing material on the exposed surface so as to cover at least a connection portion at which the conductive cable and the conductive pattern are connected.
10. The method for manufacturing a glass plate module according to claim 9, further comprising a step of arranging a spacer that extends along an edge portion of the second glass plate on the exposed surface before the step of arranging the sealing material, wherein the sealing material is arranged on the exposed surface in a region surrounded by the spacer and an end surface that extends along the notch of the first glass plate.
11. The method for manufacturing a glass plate module according to claim 10, wherein the restriction member is attached to the spacer, and the restriction member is attached along with the arrangement of the spacer.
Description
BRIEF DESCRIPTION OF DRAWINGS
[0018]
[0019]
[0020]
[0021]
[0022]
[0023]
DESCRIPTION OF EMBODIMENTS
[0024] Hereinafter, an embodiment of a case in which the glass plate module according to the present invention is applied to a windshield of an automobile will be described with reference to the drawings.
[0025] 1. Overview of Windshield
[0026] As shown in
[0027] 1-1. Laminated Glass
[0028] The laminated glass 1 includes a rectangular outer glass plate 11, a rectangular inner glass plate 12 that opposes the outer glass plate 11, and an interlayer 13 that is arranged between the two glass plates 11 and 12. The two glass plates 11 and 12 have approximately the same shape. However, a circular arc-shaped notch 121 is formed on the lower side of the inner glass plate 12, and the outer glass plate 11 is exposed from this notch 121. That is, the interlayer 13 is not arranged at the portion at which the notch 121 is formed. Hereinafter, the portion that is exposed from the notch 121 on the outer glass plate 11 will be referred to as an exposed surface 111.
[0029] 1-1-1. Glass Plate
[0030] Known glass plates can be used as the outer glass plate 11 and the inner glass plate 12, and the outer glass plate 11 and the inner glass plate 12 can also be made of heat-ray absorbing glass, regular clear glass, green glass, heat-ray absorbing glass, UV green glass, or the like. However, the glass plates 11 and 12 need to attain a visible light transmittance that conforms to the safety standards of the country in which the automobile is to be used. For example, an adjustment can be made so that the outer glass plate 11 ensures a required solar absorptance and the inner glass plate 12 provides a visible light transmittance that meets the safety standards.
[0031] Although there is no particular limitation on the thickness of the laminated glass 1 according to the present embodiment, the sum of the thicknesses of the outer glass plate 11 and the inner glass plate 12 can be set to, for example, 2.1 to 6 mm, and from the viewpoint of reducing weight, the sum of the thicknesses of the outer glass plate 11 and the inner glass plate 12 is preferably set to 2.4 to 5.5 mm, is more preferably set to 2.6 to 5.2 mm, and is particularly preferably set to 2.7 to 5.0 mm.
[0032] The outer glass plate 11 is mainly required to have durability and impact resistance with respect to external hindrances, and for example, when this laminated glass is used as a windshield of an automobile, an impact-resistance performance with respect to flying objects such as small stones is required. On the other hand, the greater the thickness is, the greater the weight is, which is not preferable. From this viewpoint, the thickness of the outer glass plate 11 is preferably 1.6 to 3.0 mm, and more preferably 1.9 to 2.8 mm.
[0033] Although the thickness of the inner glass plate 12 can be made equal to that of the outer glass plate 11, the thickness can be made smaller than that of the outer glass plate 11, for example, in order to reduce the weight of the laminated glass. Specifically, considering the strength of the glass, the thickness is preferably 0.6 to 3.0 mm, preferably 0.8 to 2.8 mm, and particularly preferably 0.9 to 2.6 mm. The thickness is even more preferably 1.0 to 2.5 mm.
[0034] Also, although the laminated glass 1 is commonly curved so as to be convex on the vehicle exterior side, the positions at which the thickness is measured in such a case are two upper and lower positions on a central line S that extends in the up-down direction in the center in the left-right direction of the laminated glass 1. Although there is no particular limitation to the measurement device, for example, a thickness gauge such as SM-112 manufactured by Teclock Corporation can be used. During measurement, the curved surface of the laminated glass 1 is arranged on a flat surface, and measurement is performed with the end portion of the laminated glass 1 sandwiched by the above-described thickness gauge. Note that even if the glass plate is flat, it is possible to perform measurement similarly to the case in which the glass plate is curved.
[0035] 1-1-2. Interlayer
[0036] The interlayer 13 is made of at least one layer, and as one example, the interlayer 13 can be constituted by three layers obtained by sandwiching a soft core layer between outer layers that are harder therethan. However, there is no limitation to this configuration, and it is sufficient that the interlayer 13 is made of multiple layers including a core layer and at least one outer layer that is arranged on the outer glass plate 11 side.
[0037] As a specific material, for example, the outer layer can be constituted by polyvinyl butyral resin (PVB). Polyvinyl butyral resin has excellent adhesiveness with glass plates and excellent penetration resistance, and is therefore preferable. On the other hand, for example, the core layer can be constituted by ethylene vinyl acetate resin (EVA), or polyvinyl acetal resin that is softer than the polyvinyl butyral resin constituting the outer layer. Due to the soft core layer being sandwiched therebetween, it is possible to significantly improve the soundproofing performance while maintaining adhesiveness and penetration resistance that are the same as those of the single-layer resin interlayer.
[0038] The total thickness of the interlayer 13 is not particularly specified, but is preferably 0.2 to 3.0 mm, more preferably 0.25 to 2.8 mm, and particularly preferably 0.3 to 2.5 mm. Also, the thickness of the core layer is preferably 0.03 to 1.0 mm and more preferably 0.05 to 0.6 mm. Also, the thickness of each outer layer is preferably 0.05 to 2.0 mm and more preferably 0.08 to 1.0 mm. Alternatively, it is also possible to make the total thickness of the interlayer 13 constant and adjust the thickness of the core layer therein.
[0039] The thicknesses of the core layer and the outer layer can be measured as follows, for example. First, across-section of laminated glass is displayed enlarged 175-fold using a microscope (e.g., VH-5500 manufactured by Keyence Corporation). Then, the thicknesses of the core layer and the outer layer are visually identified and measured. At this time, in order to remove variation resulting from eyesight, measurement is performed 5 times, and the average value is taken as the thickness of the core layer and the outer layer. For example, an enlarged photograph of a cross-section of the laminated glass is taken, and the thickness is measured by specifying the core layer and the outer layer in the photograph.
[0040] Note that the thicknesses of the core layer and the outer layer of the interlayer 13 do not need to be constant over the entire surface, and for example, it is also possible to form them into a wedge shape for use in laminated glass to be used in a head-up display. In this case, the thicknesses of the core layer and the outer layer of the interlayer 13 are measured at the thinnest location, that is, the portion on the lowermost side of the laminated glass. If the interlayer 13 is wedge-shaped, the outer glass plate and the inner glass plate are not arranged in parallel, but it is assumed that such an arrangement is included in the glass plate of the present invention as well. That is, for example, the arrangement of the outer glass plate and the inner glass plate used when using an interlayer 13 that uses a core layer and an outer layer whose thicknesses increase with a change rate of 3 mm or less per meter is included in the present invention. Note that laminated glass in which not the interlayer 13 but, for example, at least one of the outer glass plate 11 and the inner glass plate 12 is wedge-shaped can also be used as the laminated glass for use in a head-up display.
[0041] 1-2. Deicer
[0042] As shown in
[0043] Then, as shown in
[0044] 1-3. Restriction Members, Spacer, and Sealing Material
[0045] As shown in
[0046] As shown in
[0047] Also, the restriction members 3 that restrict the conductive cables 2 from separating from the exposed surface 111 are attached to the spacer 4. As shown in
[0048] Also, as shown in
[0049] 1-4. Molded Member
[0050] The molded member 6 is a member that is provided along the lower side of the windshield, and is for fixing the windshield to the vehicle interior and preventing the entrance of moisture from the vehicle exterior. Specifically, as shown in
[0051] There is no particular limitation on the shape of the molded member 6, and although the molded member 6 is attached to the windshield so as to sandwich the surface of the spacer 4 and the end surface on the lower side of the outer glass plate 11 in the examples shown in
[0052] 2. Method for Manufacturing Windshield
[0053] Next, one example of a method for manufacturing a windshield configured as described above will be described. First, a method for manufacturing the laminated glass 1 will be described.
[0054] 2-1. Method for Manufacturing Laminated Glass
[0055] First, the notch 121 is formed on the flat plate-shaped inner glass plate 12. Next, a material for use in a conductive pattern is printed on the surface on the vehicle interior side of the outer glass plate 11 through printing, and thereafter, the conductive patterns 7 and 8 are fixed to the outer glass plate 11 by baking the material. Next, the outer glass plate 11 and the inner glass plate 12 are molded into curved shapes. There is no particular limitation on the method of molding, and a known method can be employed. For example, a flat plate-shaped glass plate passes through a heating furnace, and can thereafter be molded into a curved shape by being pressed by an upper mold and a lower mold. Alternatively, the flat plate-shaped outer glass plate and inner glass plate are overlaid on each other, arranged on a frame-shaped mold, and passed through a heating furnace. Accordingly, both glass plates are softened, and are molded into curved shapes by their own weight.
[0056] After the outer glass plate 11 and the inner glass plate 12 are molded into curved shapes in this manner, the interlayer 13 is sandwiched between the outer glass plate 11 and the inner glass plate 12, and these are placed in a rubber bag, and preliminarily bonded together at about 70 to 110° C. under vacuum suction. Preliminary bonding can be performed using a method other than this method. For example, the interlayer 13 is sandwiched between the outer glass plate 11 and the inner glass plate 12 and heated at 45 to 65° C. using an oven. Next, the laminated glass is pressed by a roller at 0.45 to 0.55 MPa. Next, the laminated glass is heated again using an oven at 80 to 105° C., and thereafter is again pressed by a roller at 0.45 to 0.55 MPa. Thus, preliminary bonding is finished.
[0057] Next, permanent bonding is performed. The laminated glass subjected to preliminary bonding is subjected to permanent bonding using an autoclave at, for example, 8 to 15 atmospheres and 100 to 150° C. Specifically, for example, permanent bonding can be performed under the conditions of 14 atmospheres and 145° C. Thus, the laminated glass 1 according to the present embodiment is manufactured.
[0058] 2-2. Attachment of Conductive Cable
[0059] Next, the conductive cables 2 are connected to the power supply portions 71 and 81 arranged on the exposed surface 111 using the lead-free solder 21. Then, the spacer 4 to which the restriction members 3 have been attached is fixed to the exposed surface 111. At this time, the positions of the conductive cables 2 are adjusted such that the engagement portions 31 of the restriction members 3 engage with the conductive cables 2. Also, the conductive cables 2 extend past the spacer 4 toward the lower portion of the windshield. Thereafter, filling with the sealing material 5 is performed so as to cover the conductive patterns 7 and 8, the lead-free solder 21, the conductive cables 2, and the restriction members 3, which are arranged on the exposed surface 111. Finally, when the molded member 6 is attached to the lower side of the laminated glass 1, the windshield according to the present embodiment is complete.
[0060] 3. Characteristics
[0061] As described above, according to the present embodiment, it is possible to obtain the following effects.
(1) Although the conductive cables 2 are fixed to the power supply portions 71 and 81 using the lead-free solder 21, for example, the lead-free solder 21 is harder compared to leaded solder, and therefore there is a risk that a crack will occur when pulled unintentionally. Also, depending on the sealing material 5, it takes several days to several weeks to completely harden in some cases, and therefore the glass plate module needs to be handled in a state in which the fixing of the conductive cables 2 by the sealing material 5 is insufficient before the sealing material 5 hardens. There is also a risk that the conductive cables 2 will separate from the sealing material 5 if pulled during this time. In contrast to this, in the present embodiment, the restriction members 3 are attached to the spacer 4 fixed strongly by adhesive or double-sided tape, and the conductive cables 2 are engaged with the restriction members 3. Accordingly, the conductive cables 2 are indirectly fixed to the spacer 4, and the conductive cables 2 are prevented from separating from the exposed surface 111.
[0062] Accordingly, it is possible to prevent the conductive cables 2 from separating from the sealing material 5 even if the conductive cables 2 are pulled before the sealing material 5 hardens. Also, since it is possible to suppress a case in which a force acts also on the connection portions at which the supply portions 71 and 81 and the conductive cables 2 are connected, which are fixed by the lead-free solder 21, it is possible to prevent the lead-free solder 21 from being damaged even if the conductive cables 2 are pulled. Note that since the conductive cables 2 are covered by the sealing material 5 on the exposed surface 111, when the sealing material 5 hardens, the conductive cables 2 are firmly fixed on the exposed surface 111.
[0063] Note that depending on the material, there is a risk that even if the sealing material 5 is an elastic material, the shape will not be able to return in response to a strong deformation. Also, even after hardening, there is a possibility that the sealing material 5 will soften due to being in a high-temperature environment resulting from solar radiation and the outside air temperature, or due to heat from a terminal resulting from electrical conduction. Accordingly, even after hardening, there is a risk that an inconvenience will occur, such as the sealing material 5 deforming so as not to be able to return due to a strong force being applied to the conductive cables 2, peeling occurring due to the sealing material 5 deforming when the conductive cables 2 are pulled at a high temperature, or the conductive cables 2 coming off of the power supply portion 71. Accordingly, if the restriction member 3 has been provided as in the present embodiment, the load on the sealing material 5 and the lead-free solder 21 can be mitigated, and these inconveniences can be prevented.
[0064] (2) In particular, in the present embodiment, the conductive cables 2 extend downward from the exposed surface 111 past the spacer 4, and therefore the conductive cables 2 are guided in a direction of separating from the exposed surface 111 by the spacer 4. Accordingly, a force is likely to act on the conductive cables 2 in the direction of separating from the exposed surface 111. For this reason, if the restriction members 3 are provided as described above, the movement of the conductive cables 2 is restricted, which is particularly advantageous.
[0065] 4. Variations
[0066] Although an embodiment of the present invention has been described above, the present invention is not limited to the above-described embodiment, and various modifications are possible without departing from the gist of the invention. Also, the multiple variations described hereinafter can be combined as appropriate.
[0067] <4-1>
[0068] There is no particular limitation to the configuration of the restriction members 3, and it is sufficient that the restriction members 3 are configured to be fixed to the spacer 4 and to suppress a case in which the conductive cables 2 separate from the exposed surface 111. For example, as shown in
[0069] Alternatively, it is also possible to directly fix the restriction member 3 to the exposed surface 111 without providing the restriction member 3 on the spacer 4. For example, a restriction member 3 that is U-shaped, J-shaped, L-shaped, or the like can be engaged with the conductive cable 2 and fixed to the exposed surface 111 with adhesive, double-sided tape, or the like. It is also possible to form the restriction member 3 with tape or the like and fix the conductive cable 2 to the exposed surface 111.
[0070] <4-2>
[0071] In the above-described embodiment, the recess 42 was provided in the spacer 4, but this is one example of a mode of the spacer 4, and it is possible to use various shapes, such as an inner spacer of a recess. Note that the spacer 4 is not necessarily needed. In this case, it is sufficient that the sealing material 5 is prevented from protruding excessively from the exposed surface 111. Also, the sealing material 5 need not fill the entirety of the exposed surface 111, and for example, may be arranged so as to cover the conductive cable 2 only at the location at which the conductive cable 2 has been arranged.
[0072] <4-3>
[0073] In the above-described embodiment, the conductive patterns 7 and 8 for the deicer were provided on the windshield, but there is no particular limitation to the number and shape of the conductive patterns 7 and 8. Accordingly, there is no particular limitation to the configurations of the above-described wire materials 72 and 82 and the power supply portions 71 and 81, and it is sufficient to use a configuration in which the location of any of the conductive patterns 7 and 8 can be connected to the conductive cables 2 on the exposed surface 111.
[0074] Also, as long as electrical power can be supplied by the conductive cable 2, application of the conductive pattern is not limited to a deicer. For example, it is also possible to use a conductive pattern that is to be used in an antenna, a heating wire for preventing fogging, and the like.
[0075] Also, in the above-described embodiment, the conductive patterns 7 and 8 were formed on the outer glass plate 11 through printing, but they can also be formed on the inner glass plate 12. Alternatively, the conductive patterns 7 and 8 may also be formed on the interlayer 13. In this case, the conductive patterns 7 and 8 are formed on one of the layers forming the interlayer 13. For example, the interlayer 13 obtained by sandwiching a resin layer on which the conductive patterns 7 and 8 have been formed between other resin layers can also be provided.
[0076] <4-4>
[0077] In the above-described embodiment, the conductive cables 2 and the conductive patterns 7 and 8 are electrically connected to each other by the lead-free solder 21, but there is no limitation to this, and it is possible to employ leaded solder or the like, as long as it can electrically connect the conductive cables 2 and the conductive patterns 7 and 8.
[0078] <4-5>
[0079] There is also no particular limitation to the configuration of the laminated glass 1. In the above-described embodiment, the circular arc-shaped notch 121 is formed, but there is no particular limitation to the shape of the notch 121, and it is sufficient to use a shape in which a portion of the outer glass plate 11 appears as the exposed surface 111 on which the conductive cable 2 can be connected. Also, the notch 121 need not be obtained by removing a portion of the inner glass plate 12, and for example, it is sufficient that the inner glass plate 12 is formed smaller than the outer glass plate 11, and a portion of the outer glass plate 11 is exposed. In this case, a portion extending along the exposed surface 111 on the inner glass plate 12 is a notch of the present invention.
[0080] In the above-described embodiment, the notch 121 was provided on the inner glass plate 12 and the exposed surface 111 was provided on the outer glass plate 11, but the inverse of this may also be employed.
[0081] A mask layer can also be provided on at least one glass plate as needed. A mask layer can be formed on the peripheral edge of the glass plate using ceramics or the like, and thus the field of view from the vehicle exterior or the vehicle interior is blocked.
[0082] The molded member 6 need only be provided as needed according to the specification of the automobile, and it is also possible to use a windshield that does not include a molded member.
[0083] <4-6>
[0084] In the above-described embodiment, an example was shown in which the glass plate module of the present invention was applied to the windshield, but it is also possible to apply the glass plate module of the present invention to a rear glass, a side glass, or the like. For example, if the glass plate module of the present invention is applied to a rear glass, the conductive pattern can be for a defogger or an antenna.
LIST OF REFERENCE NUMERALS
[0085] 1 Laminated glass (glass assembly) [0086] 11 Outer glass plate (first glass plate) [0087] 12 Inner glass plate (second glass plate) [0088] 13 Interlayer [0089] 2 Conductive cable [0090] 3 Restriction member [0091] 4 Spacer [0092] 5 Sealing material [0093] 7 First conductive pattern [0094] 8 Second conductive pattern