Method and apparatus for forming a vehicle window assembly using induction soldering

Abstract

Induction soldering via an assembly fixture is utilized to bond one or more items of hardware to a vehicle window to form a vehicle window assembly. A method of operating the assembly fixture to bond the one or more items of hardware to a vehicle window by induction soldering is also an aspect of the invention.

What is claimed is: 
     
         1 . A method of forming a vehicle window assembly comprising:
 providing a vehicle window having a major inner surface with an electrically conductive material disposed on at least a predetermined area thereof, a major outer surface and a peripheral edge portion therearound;   placing the vehicle window on an assembly fixture having one or more induction coil assemblies and one or more movable assembly aids mounted on the assembly fixture, wherein the major outer surface of the vehicle window faces the assembly aid;   disposing one or more items of hardware having a predetermined amount of solder thereon, in the one or more movable assembly aids;   energizing the one or more induction coil assemblies proximate the major outer surface of the vehicle window to selectively direct one or more electromagnetic fields through the vehicle window causing heating of the one or more areas of the major inner surface of the vehicle window upon which the electrically conductive material is disposed to a temperature sufficient to liquefy the solder on the one or more items of hardware; and   moving the one or more assembly aids into a position proximate the one or more heated areas of the major inner surface of the vehicle window and causing one or more items of hardware in the one or more assembly aids to move into bonding contact with the one or more heated areas of the major inner surface of the vehicle window.   
     
     
         2 . The method defined in  claim 1 , wherein the one or more assembly aids is moved proximate the vehicle window by a rotating assembly in an arc-like manner. 
     
     
         3 . The method defined in  claim 1 , wherein the electrically conductive material is heated to a temperature of between 100° F. and 600° F. 
     
     
         4 . The method defined in  claim 3 , wherein the electrically conductive material is heated to the desired temperature in less than 20 sec at a power output of >1000 W per induction coil assembly. 
     
     
         5 . A method of forming a vehicle window assembly comprising:
 providing a vehicle window having a major inner surface with an electrically conductive material disposed on one or more predetermined areas thereof, a major outer surface, and a peripheral edge portion;   placing the vehicle window on an assembly fixture comprising a major component mounting surface, having at least the following components mounted thereon:
 one or more resilient vertical gaseous positioning members; 
 one or more induction coil assemblies; 
 one or more fixed or movable x-y positioning members, and 
 one or more movable assembly aids having as a component thereof, one or more hardware holding members, each hardware holding member having one or more items of hardware disposed therein, each item of hardware having a predetermined amount of solder disposed thereon, wherein the major outer surface of the vehicle window faces the major component mounting surface of the assembly fixture; 
   activating the one or more x-y positioning members to properly position the vehicle window on the assembly fixture in an x-y plane;   applying a negative gaseous pressure through the one or more resilient vertical gaseous positioning members to draw the major outer surface of the vehicle window into intimate contact with a resilient portion of the one or more resilient vertical gaseous positioning members through movement in a z direction and proximate, but not in intimate contact with, the one or more induction coil assemblies;   energizing the one or more induction coil assemblies proximate the major outer surface of the vehicle window to selectively direct one or more electromagnetic fields into the vehicle window, causing heating of the major inner surface of the vehicle window particularly in the one or more predetermined areas thereof having the electrically conductive material disposed thereon, wherein the electrically conductive material is heated to a temperature of between 100° F. and 600° F. in less than 20 sec at a power output of >1000 W per induction coil assembly;   activating the one or more assembly aids to move the one or more hardware holding members into a position proximate the one or more heated areas of the major inner surface of the vehicle window;   discharging the one or more items of hardware from the one or more hardware holding members so that the one or more items of hardware come into bonding contact with the one or more predetermined areas of the major inner surface having the electrically conductive material disposed thereon, the major inner surface of the vehicle window and/or the item of hardware being heated to a temperature sufficient to melt the solder disposed on the one or more items of hardware, wherein the bonded area between the item of hardware and the heated portion of the vehicle window is >50% of the total possible bonding area;   de-energizing the one or more induction coil assemblies to allow the vehicle window to cool and the one or more items of hardware to bond to the major inner surface of the vehicle window;   discontinuing the negative gaseous pressure applied through the one or more resilient vertical gaseous positioning members; and   removing the vehicle window with one or more items of hardware bonded to the major inner surface thereof from the assembly fixture.   
     
     
         6 . The method defined in  claim 5 , wherein the electrically conductive material comprises a ceramic frit material. 
     
     
         7 . The method defined in  claim 5 , wherein the one or more hardware holding members are attached to a first end of one or more support arms. 
     
     
         8 . The method defined in  claim 7 , wherein a second end of the one or more support arms is connected to a rotatable shaft. 
     
     
         9 . The method defined in  claim 8 , wherein the shaft is rotated thus causing the attached assembly aid to move in an arc-like fashion, the arc being up to about 180°, so as to position the hardware holding member proximate the major inner surface of the vehicle window. 
     
     
         10 . The method defined in  claim 5 , wherein one or more recesses for holding items of hardware are formed in the hardware holding member. 
     
     
         11 . The method defined in  claim 10 , wherein at least a portion of the one or more recesses extends through the material of the assembly aid to form an opening therein. 
     
     
         12 . The method defined in  claim 11 , wherein at least one pneumatic cylinder having an extendable anterior member is aligned with the one or more openings in the assembly aid. 
     
     
         13 . The method defined in  claim 12 , wherein the anterior member of the at least one pneumatic cylinder is activated so as to extend through the opening in the assembly aid and contacts an item of hardware disposed in the at least one recess in the assembly aid, causing the item of hardware to be discharged from the assembly aid and to come into bonding contact with the heated major inner surface of the vehicle window. 
     
     
         14 . An assembly fixture for forming a vehicle window assembly comprising:
 a major component mounting surface having at least the following components mounted thereon:
 one or more resilient vertical gaseous positioning members located so as to support a vehicle window a predetermined distance above the major component mounting surface, wherein the resilient vertical positioning member is connected to a source of positive and negative gaseous pressure; 
 one or more induction coil assemblies comprising:
 a base member mounted to the major component mounting surface; 
 
 one or more induction coils mounted on the base member and extending a predetermined vertical distance above the base member; 
 at least one non-abrasive material covering the portion of the induction coil which is proximate a major outer surface of the vehicle window, when such vehicle window is placed on the assembly fixture; 
 one or more fixed or movable x-y positioning members; 
 one or more assembly aids comprising:
 a base plate mounted to the major component mounting surface; 
 at least one bearing mount attached to the base plate 
 a rotatable shaft extending through the at least one bearing mount; 
 the rotatable shaft also extending through a second end of at least one support arm; 
 at least one hardware holding member attached to a first end of the at least one support arm; 
 one or more hardware retention recesses formed in the hardware holding member; 
 one or more openings extending through the hardware retention recess and being connected to a source of positive and negative gaseous pressure; 
 the rotatable shaft connected to a motor, 
 
   wherein the operation of the components of the assembly fixture is controlled by one or more electronic controllers, and the one or more electronic controllers are connected to a source of electric power.   
     
     
         15 . The assembly fixture defined in  claim 14 , wherein the assembly aid comprises at least one pneumatic cylinder having an extendable anterior member is aligned with the one or more openings in the hardware retention recess. 
     
     
         16 . The assembly fixture defined in  claim 14 , wherein the assembly aid comprises at least one hydraulic cylinder having an extendable anterior member is aligned with the one or more openings in the hardware retention recess. 
     
     
         17 . The assembly fixture defined in  claim 14 , wherein the major component mounting surface comprises a metal plate. 
     
     
         18 . The assembly fixture defined in  claim 14 , wherein the one or more induction coil assemblies each have a power output >1000 W. 
     
     
         19 . The assembly fixture defined in  claim 18 , wherein the power output of the induction coil assembly is capable of being selectively directed into an area of the substrate >10 mm 2 . 
     
     
         20 . The assembly fixture defined in  claim 19 , wherein the induction coil assembly is capable of heating the chosen area of the substrate to a temperature up to 600° F. in less than 20 sec.