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US-20260124823-A1 - FOLDED FLEXIBLE CIRCUIT FOR AUTOMOTIVE LAMINATE

US20260124823A1US 20260124823 A1US20260124823 A1US 20260124823A1US-20260124823-A1

Abstract

The complexity of modern automotive glazing is increasing as more and more technology is being integrated with the glazing. As the industry moves towards full autonomous electric vehicles and as consumers demand increased levels of comfort, convenience, and safety this trend will only increase. It is now common to have electrical components embedded within laminated glazing. However, making electrical connections to embedded components can be challenging. The flexible circuit of the disclosure, which can provide an electrical connection to multiple complex circuits, comprises a flexible circuit with at least one insulating layer, at least one conductive layer and with at least one sharp fold in the flexible circuit. This approach substantially reduces the quantity of material that is wasted, facilitates assembly of the laminate, and reduces cost.

Inventors

  • Araz DARBA
  • Andrés Fernando Sarmiento Santos
  • Rafael AGUILERA

Assignees

  • AGP WORLDWIDE OPERATIONS GMBH

Dates

Publication Date
20260507
Application Date
20231002

Claims (20)

  1. 1 . A flexible electrical circuit configured to be embedded into a laminated glazing for a vehicle, comprising: at least one insulating layer; at least one conductive layer bonded to at least one insulating layer; and at least one folded area having a sharp fold in said flexible circuit wherein the flexible circuit is folded over onto itself forming a crease.
  2. 2 . The flexible electrical circuit of the preceding claim , having at least a portion configured to provide a folded area with a crease such as to obtain two segments on each side of the crease that change directions.
  3. 3 . The flexible electrical circuit of any of the preceding claims , wherein the total thickness of the flexible electrical circuit comprising all of the at least one insulating and the at least one conductive layers is equal to or above 25 μm and equal to or less than 1000 μm.
  4. 4 . The flexible electrical circuit of any of the preceding claims , wherein the thickness of the at least one sharp fold crease is reduced when compared to the total thickness of the portion immediately adjacent which comprises all of the at least one insulating and at least one conductive layers.
  5. 5 . The flexible electrical circuit of any of the preceding claims , wherein the radius of the at least one sharp fold is less than or equal to the thickness of the flexible circuit.
  6. 6 . The flexible electrical circuit of any of the preceding claims , wherein the total thickness in the folded area is less than double the total thickness of the portion immediately adjacent which comprises all of the of the at least one insulating and at least one conductive layers.
  7. 7 . The flexible electrical circuit of any of the preceding claims , wherein a portion of at least one insulating layer is removed in the folded area.
  8. 8 . The flexible electrical circuit of any of the preceding claims , wherein a portion of at least one of the at least one insulating layer is removed following the crease line in such a way that on one side of the crease the insulating layer is present and on the other side of the crease the insulating layer is partially removed.
  9. 9 . The flexible electrical circuit of any of the preceding claims , wherein the total thickness in the folded area is less than one and one half the total thickness of the portion immediately adjacent that comprises all of the of the at least one insulating and at least one conductive layer.
  10. 10 . The flexible electrical circuit of any of the preceding claims , wherein the total thickness in the folded area is substantially the same or less than that of the total thickness of the portion immediately adjacent that comprises all of the of the at least one insulating and at least one conductive layer.
  11. 11 . The flexible electrical circuit of any of the preceding claims , wherein the width of the at least one conductive layer is increased in the folded area.
  12. 12 . The flexible electrical circuit of any of the preceding claims , wherein the at least one conductive layer is comprised of copper.
  13. 13 . A laminated glazing, comprising: at least two glass layers with each comprising two oppositely disposed major surfaces and an edge surface; at least one bonding interlayer wherein said interlayer is positioned between major surfaces of the at least two glass layers; at least one electrical component embedded within said laminated glazing; and a flexible electrical circuit of any of the preceding claims which is connected to said at least one electrical component, and is at least partially embedded to said laminated glazing.
  14. 14 . The laminated glazing of claim 13 , wherein the thickness of the at least one sharp fold of the flexible circuit is less than or equal to one third of the total thickness of all of the at least one bonding interlayer.
  15. 15 . The laminated glazing of any of claims 13 and 14 , wherein the at least one electrical component is selected from the following list: an SPD film, an LC film, a PDLD film, an LED, a touch sensor, a distance sensor, an antenna, a temperature sensor, a display, an RFID, a sound transducer, a heated circuit.
  16. 16 . The laminated glazing of any of claims 13 to 15 , wherein at least one portion of the flexible circuit exits the edge of the at least two glass layers by extending outboard them.
  17. 17 . The laminated glazing of claim 16 , wherein the at least one portion of the flexible circuit that extends outboard of the edge of the at least two glass is reinforced.
  18. 18 . The laminated glazing of any of claims 13 to 15 , wherein the flexible circuit is electrically connected to a second flexible circuit or connector which exits the edge of the at least two glass layers.
  19. 19 . The laminated glazing of any of claims 13 to 18 , wherein the glazing is a sidelite window, roof, windshield or backlite.
  20. 20 . A vehicle comprising the glazing of any of claims 13 to 19 .

Description

FIELD OF THE DISCLOSURE The disclosure is related to the field of laminated automotive glazing. BACKGROUND OF THE DISCLOSURE The complexity of modern automotive glazing has been increasing at a rapid rate as the result of a number of trends in the automotive industry. In response to the regulatory requirements for increased automotive fuel efficiency as well as the growing public awareness and demand for environmentally friendly products, automotive original equipment manufacturers, around the world, have been working to improve the efficiency of their vehicles. One of the widely employed methods to improve efficiency has been to reduce vehicle weight. This is sometimes accomplished by increasing the glazed area of the vehicle, displacing heavier materials with glass and plastic. This is often done in conjunction with a reduction in the overall size of the vehicle. Unfortunately, the reduction in cabin volume can lead to an undesirable, cramped, and claustrophobic feel. However, it has been found that increasing the glazed area, in addition to reducing weight, helps to offset this effect by giving the occupants a wider field of view and admitting more natural light. Roof glazing is highly effective in this respect. Roof glazing, once limited to an area immediately above the front seat, have been getting larger and larger. We now see roof glazing that comprise a substantial portion of the vehicle roof. These large glazing are known as panoramic roofs. A panoramic roof is comprised substantially of glass. The roof glazing may be comprised of a single or multiple glazing. One or more of the glazing may be fixed or movable. The glazing may be laminated, tempered or a mixture of both types. The large panoramic glass roof gives the vehicle an airy and luxurious look. On new cars, the panoramic roof has become a popular option that has seen rapid growth over the last several years. In recent years, on models offered with a panoramic roof offered as an option the take rate has been high. This trend is predicted to accelerate in the coming years. Interestingly, while the predecessor to the panoramic roof, the “sunroof”, let in light and could be opened to let in air, panoramic roofs sometimes have panels that are fixed in place and do not open. Models equipped with panoramic roofs that open require complex and expensive mechanisms that tend to be prone to warranty issues. In addition, panoramic roofs sometimes do not let very much light into the vehicle. Due to the large surface area exposed to the sun, the panoramic roof is often designed to transmit as little as 3% visible light to reduce the need for a shade, another added cost and potential warranty item. The panoramic roof may be one option that is purchased more for appearance and aesthetics rather than function. Another important trend is the move toward full autonomous operation. Today, most new vehicles come with some level of automated driver assistance system, ADAS, as standard equipment. Automated driver assistance systems are just one of the innovative technologies that the vehicle glazing has become an integral and essential part of. Many of the automotive manufacturers are now making driver assistance systems, which were an expensive option not too many years ago, standard equipment on many if not all of their models. With the vehicle glazing occupying a large percent of the vehicle exterior and interior surface area, it is increasingly being integrated with the various sensors and other components needed to enable the driver assist systems. Another trend is the transition from internal combustion engine (ICE) powered vehicles to full electric. Most large automobile manufacturers have announced plans to transition from primarily ICE powered vehicles to battery powered full electric. We have also seen several new automobile manufacturers emerge producing battery electric vehicles exclusively. One of the challenges of full electric battery powered vehicles is range. The reduction in range due to the heating and cooling load of the vehicle is especially a problem due to the substantial amount of energy required. The typical internal combustion engine (ICE) powered vehicle is not extremely efficient at turning the energy from the fuel into kinetic energy. More of the energy is converted into heat than motion. Managing this waste heat has long been one of the major challenges faced in the design of this type of vehicle. However, one of the benefits of this inefficiency is that it provides a ready and essentially free source of power for heating the cabin and clearing the glazing of ice and fog. The typical ICE vehicle is equipped with a hot air system having a capacity of 4,000 watts or greater. This compares to the 1,000-1,500-watt capacity of the typical automotive electrical alternator. However, as the efficiency of ICE vehicles has increased, some high efficiency, small displacement engine vehicles, especially those sold in parts of the world with a co