WO2016189272A1

WO2016189272A1 - Method of making an automotive window assembly and an apparatus for making the same

Info

Publication number: WO2016189272A1
Application number: PCT/GB2016/051371
Authority: WO
Inventors: Matthew A RAPIN; Douglas G BURWELL; Julia Bronwen MACLACHLAN
Original assignee: Pilkington Group Ltd
Current assignee: Pilkington Group Ltd
Priority date: 2015-05-26
Filing date: 2016-05-12
Publication date: 2016-12-01
Anticipated expiration: 2017-11-26

Abstract

A method of making an automotive window assembly includes providing a glass substrate having a bonding surface. A first primer is applied over a portion of the bonding surface. An adhesive is applied to a surface of a polymeric member. The adhesive on the surface of the polymeric member faces the bonding surface of the glass substrate. An ultrasonic bonding apparatus is provided. The ultrasonic bonding apparatus receives a portion of the polymeric member. The ultrasonic bonding apparatus generates a predetermined amount of ultrasonic energy and converts the ultrasonic energy into mechanical energy. The mechanical energy is transferred to the polymeric member to generate heat in the adhesive and bond the polymeric member to the glass substrate.

Description

METHOD OF MAKING AN AUTOMOTIVE WINDOW ASSEMBLY AND AN

APPARATUS FOR MAKING THE SAME

CROSS-REFERENCE TO RELATED APPLICATION This application is claiming the benefit, under 35 U.S. C. 1 19(e), of the provisional U.S. patent application which was granted Serial No. 62/166,256 and filed on May 26, 2015, the entire disclosure of which is hereby incorporated by reference.

TECHNICAL FIELD

The invention relates to a method of making an automotive window assembly.

Also, the invention relates to an apparatus for making the automotive window assembly.

In particular, the invention relates to a method of, and apparatus for, making an automotive window assembly utilizing an ultrasonic bonding apparatus.

BACKGROUND OF THE INVENTION

It is known to employ ultrasonic energy in the bonding of parts. US 3,284,257 relates to a method of bonding non-thermoplastic parts by sonic energy. Furthermore, US 3,480,492 seeks to improve upon the invention disclosed in US 3,284,257 by providing an ingredient which undergoes an exothermic reaction causing an increase in temperature above that obtained using sonic energy alone. However, these techniques are not described in relation to windows or window assemblies.

As is known, windows are utilized in vehicles for visibility and to close openings in the body of the vehicle. Often, it is desirable to bond hardware to the front window or windshield of the vehicle. However, the methods of bonding known in the art such as, for example, double sided tape and traditional adhesive bonding lack sufficient strength and require long cure times.

US 6, 103,034 discloses a method and apparatus for welding a hard resin product to a substrate. The substrate may be glass, and the hard resin product may be subjected to ultrasonic vibration while it is applied to the substrate. Also, US 7,842,146 discloses applying ultrasonic energy to an adhesive to enhance the bonding of the adhesive to a surface of a substrate.

The inventions disclosed in the above documents have not entirely overcome the aforementioned deficiencies. Therefore, it would be advantageous to provide a method and apparatus which improve upon the prior art.

SUMMARY OF THE INVENTION

The present invention provides embodiments of a method of making an automotive window assembly. In an embodiment, the method comprises providing a glass substrate having a bonding surface. A first primer is applied over a portion of the bonding surface. An adhesive is applied to a surface of a polymeric member. The adhesive on the surface of the polymeric member faces the bonding surface of the glass substrate. An ultrasonic bonding apparatus is provided. The ultrasonic bonding apparatus receives a portion of the polymeric member. The ultrasonic bonding apparatus generates a predetermined amount of ultrasonic energy and converts the ultrasonic energy into mechanical energy. The mechanical energy is transferred to the polymeric member to generate heat in the adhesive and bond the polymeric member to the glass substrate. Therefore, according to the present invention, there is provided a method of making an automotive window assembly, comprising

providing a glass substrate having a bonding surface;

applying a first primer over a portion of the bonding surface;

applying an adhesive to a surface of a polymeric member, the adhesive on the surface of the polymeric member facing the bonding surface of the glass substrate; providing an ultrasonic bonding apparatus, the ultrasonic bonding apparatus receiving a portion of the polymeric member, the ultrasonic bonding apparatus generating a predetermined amount of ultrasonic energy and converting the ultrasonic energy into mechanical energy, wherein the mechanical energy is transferred to the polymeric member to generate heat in the adhesive and bond the polymeric member to the glass substrate.

Preferably, the method further comprises applying a second primer over the first primer. More preferably, the adhesive is polyurethane based, and the first primer comprises a silane coupling agent, whereas the second primer is polyurethane based.

Preferably, the method further comprises forming a ceramic frit layer on the bonding surface, wherein the first primer is applied on the ceramic frit layer.

Preferably, the polymeric member comprises a base portion, an elongated generally cylindrical-shaped portion extending vertically from a first side of the base portion, and an anti-rotation protuberance extending vertically from the first side of the base portion and spaced apart from the elongated generally cylindrical-shaped portion. Preferably, the adhesive comprises a heat activated cure mechanism which is activated at a temperature of 90°C or more, more preferably at a temperature of 90 - 180°C.

Preferably, the method further comprises providing one or more protuberances on the surface of the polymeric member, each protuberance of a predetermined height and extending from a base portion of the polymeric member toward the bonding surface of the glass substrate, the predetermined height of each protuberance corresponding to a desired thickness of the adhesive.

Preferably, the adhesive separates the surface of the polymeric member from the bonding surface of the glass substrate and is disposed over the first primer.

Preferably, the method further comprises urging a portion of the ultrasonic bonding apparatus and the polymeric member toward the glass substrate so that the polymeric member is placed in an abutting relationship with the bonding surface of the glass substrate, wherein the polymeric member and bonding surface of the glass substrate are positioned relative to each other so that the adhesive is disposed over the bonding surface of the glass substrate and over the first primer.

Preferably, the ultrasonic bonding apparatus comprises a horn which comprises a facing surface, the facing surface having a major aperture which receives an elongated portion of the polymeric member and a minor aperture which receives an anti-rotation protuberance of the polymeric member. More preferably, the major aperture and the minor aperture are both in fluid communication with a source of vacuum. Preferably, the ultrasonic bonding apparatus comprises a source of ultrasonic energy, the source of ultrasonic energy being in communication with a booster, the booster receiving ultrasonic energy from the source of ultrasonic energy and converting the ultrasonic energy into mechanical energy, wherein the booster communicates the mechanical energy to a horn, the horn receiving the polymeric member. More preferably, the booster communicates mechanical energy to the horn via a hollow, cylindrical arm.

The invention also includes an automotive window assembly made according to any of the methods described above.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The above, as well as other advantages of the process will become readily apparent to those skilled in the art from the following detailed description when considered in the light of the accompanying drawings in which:

FIG. 1 is a perspective view of an embodiment of an apparatus in accordance with the invention;

FIG. 2 is a perspective exploded view of a portion of the apparatus of FIG. 1 with an embodiment of a polymeric member in accordance with the invention;

FIG. 3 depicts a side view of an embodiment of a horn suitable for use in the apparatus of FIG. 1 ;

FIG. 4 depicts a front view of the horn of FIG. 3;

FIG. 5 depicts a cross-sectional view of the horn of FIG. 3 taken along line 5-5; FIG. 6 depicts and enlarged portion of the horn of FIG. 5; FIG. 7 depicts a perspective view of another embodiment of a horn suitable for use in the apparatus of FIG. 1 ;

FIG. 8 depicts a perspective view of an automotive window assembly made in accordance with the invention; and

FIG. 9 depicts a cross-sectional view of a portion of the automotive window assembly of FIG. 8 taken along line 9-9.

FIG. 10 depicts a bottom view of another embodiment of the polymeric member in accordance with the invention; and

FIG. 1 1 depicts a cross-sectional view of a portion of the polymeric member of FIG. 10 taken along line 1 1 -1 1.

DETAILED DESCRIPTION OF THE INVENTION

It is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific apparatus and methods illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions, directions or other physical characteristics relating to the embodiments disclosed are not to be considered as limiting, unless the claims expressly state otherwise. Also, although they may not be, like elements in various embodiments may be commonly referred to with like reference numerals within this section of the application.

Referring now to FIGs. 1 -1 1 , a method of making an automotive window assembly and an apparatus 10 for making the window assembly are described below.

An example of an automotive window assembly 200 made in accordance with the method is illustrated in FIG. 8. The window assembly 200 comprises a polymeric member 12 bonded to a glass substrate 14. In certain embodiments, a molding 108 is attached to and around an edge portion of the glass substrate 14. The molding 108 can be attached to the glass substrate 14 via conventional means such as, for example, an adhesive or adhesive tape and can be formed utilizing conventional materials.

The window assembly 200 will be described in connection with a vehicle (not depicted). It would be understood by one of ordinary skill in the art that the window assembly described herein may have applications to on-highway and off-highway vehicles, also known as on-road and off-road vehicles. Furthermore, it would be understood by one of ordinary skill in the art that the invention could have industrial, locomotive, rail, marine, naval and aerospace applications.

The window assembly 200 may be used, for example, to glaze the vehicle. The window assembly 200 may be installed in any appropriate body opening of the vehicle. It is preferred that the window assembly is installed so as to be the front window or windshield of the vehicle. However, it should be appreciated that the window assembly could be utilized in another body opening in the vehicle such as, for example, in a side or rear opening of the vehicle.

Referring now to FIG. 1 , to make the window assembly 200, the glass substrate

14 is provided and loaded into a fixture 16. The fixture 16 helps to support and hold the glass substrate 14 while the polymeric member 12 is being bonded thereto. The fixture 16 includes a base 18 which supports the glass substrate 14 before and during bonding of the polymeric member 12 to the substrate 14. One or more non-slip layers 20 may be attached to the base 18 to help prevent the glass substrate 14 from moving during bonding of the polymeric member 12. The one or more non-slip layers 20 may be formed from urethane or other like materials.

On an end, a pneumatic cylinder member 22 is attached to the base 18. The pneumatic cylinder member 22 includes a shaft 24. An end of the shaft 24 extends into a housing 26 and an opposite end of the shaft is attached to the base 18 via a threaded connection. The pneumatic cylinder member 22 extends in a vertical direction from the base 18. A source of pressurized air 28 is in fluid communication with the pneumatic cylinder member 22. The pneumatic cylinder member 22 is utilized to adjust the position of a horn 30, 30A in a vertical direction relative to the glass substrate 14.

On an opposite end, the pneumatic cylinder member 22 is attached to a spacer 32. The spacer 32 is attached to a holding member 34. However, it should be appreciated that in other embodiments (not depicted), the pneumatic cylinder member may be attached directly to the holding member. As illustrated in FIG. 1 , the holding member 34 extends in a horizontal direction from the spacer 32 and pneumatic cylinder member 22 and is in a parallel relationship to the base 18. A handle portion 36 is attached to the holding member 34. The handle portion 36 is separated from the spacer 32 and the pneumatic cylinder member 22 by the holding member 34. A booster 38 is engaged with the holding member 34 and extends through a portion thereof.

The booster 38 is in communication with a source of ultrasonic energy 40 via a cable 42. The booster 38 communicates with the horn 30, 30A via an arm 44.

However, in certain embodiments (not depicted), the booster may communicate directly with the horn. The arm 44 is a hollow, cylindrical member. However, it should be appreciated that the arm may be of another shape. The arm 44 is attached to the horn 30, 30A on an end and the booster 38 on an opposite end.

Referring now to FIGs. 1 -7, a source of vacuum 46 is in fluid communication with the horn 30, 30A via the arm 44. The source of vacuum 46 and the arm 44 may be in communication via a tube fitting 48. The tube fitting 48 is attached to a side port 50 of the arm 44. A center conduit 52 is provided through the arm 44 and is in fluid communication with the tube fitting 48 via the side port 50. The center conduit 52 receives a hollow stud 54 via a center port 56. The center conduit 52 is in fluid communication with the hollow stud 54, which provides for fluid communication between the arm 44 and horn 30, 30A.

A central conduit 58 extends through the horn 30, 30A. On an end, the central conduit 58 is in fluid with the source of vacuum 46 via the center conduit 52 and hollow stud 54. On an opposite end, the central conduit 58 is in fluid communication with a major aperture 60 formed in a facing surface 62, 62A of the horn 30, 30A. Portions of the central conduit 58 may gradually increase in diameter toward the major aperture 60. In an embodiment, the central conduit 58 comprises a filleted portion 64 which is attached to the major aperture 60. The filleted portion 64 may be attached to a first cylindrical portion 66. The first cylindrical portion 66 is of a substantially constant diameter and is also attached to a reduced diameter portion 68. The reduced diameter 68 portion gradually decreases in diameter toward a second cylindrical portion 70. The reduced diameter portion 68 is attached to the second cylindrical portion 70. The second cylindrical portion 70 is of a substantially constant diameter. The diameter of the first cylindrical portion 66 is greater than the diameter of the second cylindrical portion 70. The second cylindrical portion 70 is also attached to a mating portion 72. The mating portion 72 receives an end of the hollow stud 54 for attaching the arm 44 to the horn 30, 30A.

As illustrated in FIGs. 6-7, a minor aperture 74 is also formed in the facing surface 62, 62A of the horn 30, 30A. A minor conduit 76 may be in fluid communication with the minor aperture 74. The minor conduit 76 is in fluid communication with the source of vacuum 46.

Referring back to FIGs. 3-6, in an embodiment, the horn 30 comprises a first portion 78, which may be of a generally rectangular shape, and a second portion 80, which may be of a generally rectangular shape. The first portion 78 is of a thickness which is greater than a thickness of the second portion 80. The first portion 78 is attached to the second portion 80 via a ramped transition portion 82. The ramped transition portion 82 is of a thickness which gradually decreases toward the second portion 80. The facing surface 62 is provided on the second portion 80 and may be of a generally rectangular shape.

In another embodiment, like the one shown in FIG. 7, the horn 30A comprises a first portion 78A which is of a cylindrical shape. In this embodiment, the second portion 80A is also of a cylindrical shape. The first portion 78A is of a diameter which is greater than a diameter of the second portion 80A. The first portion 78A is attached to the second portion 80A via the ramped transition portion 82A. In this embodiment, the ramped transition portion 82 is of a diameter which gradually decreases toward the second portion 80A. In this embodiment, the facing surface 62A is of a generally annular shape.

Referring now to FIGs. 8-9, a first primer 84 is applied over a portion of a bonding surface 86 of the glass substrate 14 prior to bonding the polymeric member 12 thereto. In an embodiment, a second primer 88 is also applied over the portion of the bonding surface 86 of the glass substrate 14. In this embodiment, the second primer 88 is applied over the first primer 84. Preferably, the primers 84, 88 are applied over a frit layer 90 previously formed on the bonding surface 86. Preferably, the first primer 84 is applied directly on the frit layer 90. Preferably, the frit layer 90 comprises a ceramic material.

The first primer 84 can be applied on the ceramic frit layer 90 via a pressurized flow gun, brush, or another suitable applicator. Preferably, the first primer 84 comprises a silane coupling agent. A suitable first primer is sold under Betaseal™ 43518 and is sold by the Dow Chemical Co. The method may be practiced using other first primers. Preferably, the second primer 88 is disposed on the first primer 84. The second primer 88 can be disposed on the first primer 84 via a brush or another suitable applicator. The second primer 88 may be utilized as a filter layer. In this embodiment, the second primer 88 prevents UV radiation from being transmitted to an adhesive 104. Preferably, the second primer 88 is polyurethane based. A suitable second primer is sold under Betaseal™ 43520A and is sold by the Dow Chemical Co. The method may be practiced using other second primers.

The polymeric member 12 is received by and engaged with the apparatus 10. More particularly, one or more portions of the polymeric member 12 are received by and engaged with the horn 30, 30A. Prior to being bonded to the glass substrate 14, the polymeric member 12 is positioned over the glass substrate 14. When it is desired to bond the polymeric member 12 to the glass substrate 14, the polymeric member 12 is moved in a vertical direction toward the bonding surface 86 of the glass substrate 14.

In an embodiment, the polymeric member 12 is formed from is a thermoplastic material. Due to its rigidity and durability, a preferred thermoplastic material is polybutylene terephthalate (PBT). In certain embodiments, the polymeric member 12 is a pin member. As illustrated best in FIGs. 2 and 9, the pin member includes a base portion 92 in the form of a flat plate member, having a first side 96 and a parallel but opposite second side 100. An elongated generally cylindrical-shaped portion 94 extends vertically from the first side 96 of the base portion 92. An anti-rotation protuberance 98 is spaced apart from the elongated portion 94 and also extends vertically from the first side 96 of the base portion 92.

As noted above, the ultrasonic apparatus 10 receives a portion of the polymeric member 12. More particularly, the horn 30, 30A receives the elongated portion 94 and the anti-rotation protuberance 98 of the polymeric member 12 and is engaged with polymeric member 12 by inserting the elongated portion 94 into the major aperture 60 and the anti-rotation protuberance 98 into the minor aperture 74 formed in the facing surface 62, 62A. The major aperture 60 and minor aperture 74 are spaced apart by a distance corresponding to the distance that the anti-rotation protuberance 98 is spaced apart from the elongated portion 94.

Preferably, the source of vacuum 46 is in fluid communication with the major aperture 60 and the minor aperture 74 via the central conduit 58 and minor conduit 76, respectively. The source of vacuum 46 enables a flow of air through the major aperture 60 and the minor aperture 74. A sensor (not depicted) is in fluid communication with the central conduit 58 and minor conduit 76. The sensor measures the flow of air through the conduits 58, 76. When the flow of air through each conduit 58, 76 is reduced, engagement between the polymeric member 12 and horn 30, 30A is indicated. The amount of vacuum provided by the source of vacuum 46 can be selected to allow the polymeric member 12 and the horn 30, 30A to be secured together while the polymeric member 12 is being bonded to the glass substrate 14 but allow the polymeric member 12 and the horn 30, 30A to be separated at a desired time such as, for example, when the polymeric member 12 is bonded to the glass substrate 14.

Referring back to FIGs. 2 and 9, on a second side 100 of the base portion 92, in an embodiment, two or more stand over protuberances 102 extend vertically therefrom. In an embodiment, three stand over protuberances are provided. The stand over protuberances 102 are spaced apart from each other. Preferably, each stand over protuberance 102 is in a parallel relationship with an adjacent stand over protuberance 102. In certain embodiments, each stand over protuberance 102 is of a cylindrical shape having a flat cylindrical surface defining an end thereof. When the polymeric member 12 is engaged with the ultrasonic apparatus 10, each stand over protuberance 102 extends toward the bonding surface of the glass substrate 14.

The height of each stand over protuberance 102 can be predetermined to provide for a desired adhesive thickness. The thickness of the adhesive 104 influences the cure time of the adhesive. Thus, the height of each stand over protuberance 102 may also influence the time in which it takes the adhesive 104 to cure. Therefore, the height of each stand over protuberance 102 may be selected to provide for a desired cure time. In an embodiment, the thickness of the adhesive 104 is equal to or less than the height of the stand over protuberances 102.

Referring now to FIGs. 10-1 1 , in another embodiment, the polymeric member 12 comprises an energy director 1 10. An energy director may be used to concentrate ultrasonic energy in a locally defined area, allowing higher temperatures to be reached for a given quantity of energy. The energy director 1 10 is provided to concentrate mechanical energy transmitted to the polymeric member 12, which improves bonding of the polymeric member 12 to the glass substrate 14. The energy director 1 10 is provided on the second side 100 of the base portion 92. Preferably, the energy director 1 10 is attached to the second side 100 of the base portion 92 via molding. The energy director may take the general form of a ridge, which may be straight or curved, and may or may not form a closed shape. The energy director may alternatively or additionally have the form of a triangular protrusion.

The energy director 1 10 extends from the second side 100 of the base portion 92 toward the glass substrate 14. As shown best in FIG. 1 1 , the energy director 1 10 may comprise a pair of side surfaces 1 12, 1 14. In an embodiment, each side surface 1 12, 1 14 is attached to the second side 100 of the base portion 92 and an end surface 1 16. In this embodiment, the side surfaces 1 12, 1 14 may be positioned at an acute angle relative to each other. In other embodiments (not depicted), the side surfaces may be positioned at another angle relative to each other. As is illustrated, the end surface 1 16 may be rounded. In other embodiments (not depicted), the end of the energy director may be sharply defined. In the embodiments illustrated, the energy director 1 10 is of a generally triangular shape in cross-section. However, in other embodiments (not depicted), the energy director may be of another shape in cross-section

Referring back to FIG. 10, the energy director 1 10 may comprise a first director 1 18 and a second director 120. In one such embodiment, the first director 1 18 is of a generally rectangular shape. In another embodiment (not depicted), the first director may be of another shape. In other embodiments, the second director 120 comprises one or more branches 122, 122A, 124, 124A, 126, 126A, 128, 128A. In an

embodiment, one or more of the branches 122, 122A, 124, 124A, 126, 126A, 128, 128A is linear. In another embodiment, the second director 120 may comprise branches of equal length. For example, a first branch 122 and a second branch 122A may be of the same length and a third branch 124 and a fourth branch 124A may be of the same length. Alternatively, the second director 120 may comprise branches that are of different lengths. For example, the length of the first branch 122 may be greater than the length of the third branch 124. Also, each branch 122, 122A, 124, 124A, 126, 126A, 128, is of a width and the widths of each branch 122, 122A, 124, 124A, 126, 126A, 128, 128A may equal. Alternatively, in certain embodiments (not depicted), the widths of the branches may vary.

As illustrated in FIG. 10, certain branches 122, 122A 124, 124A, 126, 126A may be in a parallel, spaced apart relationship with each other. In other embodiments, certain branches 126, 126A, 128, 128A may be connected and positioned in a perpendicular relationship with each other. In still other embodiments, certain branches 122, 128 may be positioned in a perpendicular relationship with each other but not connected. Further, in certain embodiments, two or more branches 124, 124A may be aligned.

The one or more branches 122, 122A, 124, 124A, 126, 126A of the second director 120 may be in a perpendicular relationship with one or more portions of the first director 1 18. In other embodiments, one or more branches 128, 128A of the second director 120 may be in a parallel relationship with one or more portions of the first director 1 18. In yet another embodiment, one or more branches 122, 122A, 124, 124A, 126, 126A of the second director 120 may intersect one or more portions of the first director 1 18. In other embodiments, one or more branches 128, 128A of the second director 120 may not intersect the first director 1 18.

As best illustrated in FIG. 9, the adhesive 104 is applied to the polymeric member 12. Preferably, the adhesive 104 is applied to a surface 106 of the base portion 92 on the second side 100 thereof. When the polymeric member 12 is engaged with the ultrasonic apparatus 10 or bonded to the glass substrate, the adhesive 104 faces the bonding surface 86 of the glass substrate 14. When the polymeric member 12 is bonded to the glass substrate 14, the adhesive 104 separates the surface 106 of the polymeric member 12, having the adhesive disposed thereon, from the bonding surface 86 of the glass substrate. Also, when the polymeric member 12 is bonded to the glass substrate 14, the adhesive 104 is disposed over the first primer 84 and the second primer 88. The adhesive 104 may be applied to the polymeric member 12 utilizing a gun, pump, brush, or other suitable applicator.

The adhesive 104 includes a heat activated cure mechanism. Preferably, the cure mechanism is activated at a temperature of 90°C or more. More preferably, the heat activated cure mechanism is activated at a temperature of 90 - 180 °C. The adhesive 104 may include one or more additional cure mechanisms. For example, the adhesive may comprise a moisture cure mechanism. In an embodiment, the adhesive 104 is polyurethane based. A suitable adhesive is sold under EFBOND™ HA 315 and is sold by EFTEC AG. The method may be practiced using other adhesives.

In order to provide the heat needed to activate the cure mechanism, a

predetermined amount of energy is selected. Once the predetermined amount of energy is selected, the source of ultrasonic energy 40 generates the predetermined amount of energy. The energy provided from the source of ultrasonic energy 40 can be selected to be a desired frequency. In an embodiment, the frequency is selected to be 40 kHz. In other embodiments, the method may be practiced utilizing another frequency. The source of ultrasonic energy 40 transmits the predetermined amount of energy to the booster 38 via the cable 42. The booster 38 receives the ultrasonic energy and converts the energy provided by source of ultrasonic energy 40 into mechanical energy and communicates the mechanical energy to the horn 30, 30A via the arm 44. The horn 30, 30A increases the amplitude of the mechanical energy and transfers the energy to the polymeric member 12. From the polymeric member 12, the energy is transferred to the adhesive 104 to generate heat in the adhesive and bond the polymeric member 12 to the glass substrate 14. The amount of energy transferred to the adhesive 104 is selected to raise the temperature of the adhesive to at least 90°C and activate the cure mechanism and initiate curing of the adhesive.

When it is desired to bond the polymeric member 12 to the glass substrate 14, the polymeric member 12 and the horn 30, 30A are engaged and urged toward the glass substrate 14 so that the adhesive applied to the polymeric member 12 is provided between the polymeric member 12 and the glass substrate 14. The polymeric member 12 is urged toward the glass substrate 14 until it abuts the bonding surface 86 of the glass substrate 14. Under these conditions, the polymeric member 12 and the bonding surface of the glass substrate are positioned relative to each other so that the adhesive 104 is disposed over the bonding surface 86 of the glass substrate 14 and the primers 84, 88. The polymeric member 12 can be held in an abutting relationship with the glass substrate 14 under a selected pressure. Next, mechanical energy is transmitted to the polymeric member 12 via the horn 30, 30A as described above. Also, as noted above, movement of the glass substrate 14 is prevented such that when mechanical energy is transmitted to the polymeric member 12 it oscillates relative to the fixed glass substrate 14 which creates friction. The friction between the polymeric member 12 and the glass substrate 14 generates the heat which activates the cure mechanism. After the polymeric member 12 has been bonded to the glass substrate 14, the horn 30, 30A, and polymeric member 12 are separated by moving the horn 30, 30A in a vertical direction away from the polymeric member 12 and bonding surface 86 of the glass substrate 14. After the horn 30, 30A and polymeric member 12 are separated, the glass substrate 14 can be removed from the apparatus 10 manually or in another manner.

In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiments. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its scope.

Claims

1. Method of making an automotive window assembly, comprising

providing a glass substrate having a bonding surface;

applying a first primer over a portion of the bonding surface;

2. The method of claim 1 , further comprising applying a second primer over the first primer.

3. The method of claim 1 , further comprising forming a ceramic frit layer on the bonding surface, wherein the first primer is applied on the ceramic frit layer.

4. The method of claim 1 , wherein the polymeric member comprises a base portion, an elongated generally cylindrical-shaped portion extending vertically from a first side of the base portion, and an anti-rotation protuberance extending vertically from the first side of the base portion and spaced apart from the elongated generally cylindrical- shaped portion.

5. The method of claim 1 , wherein the adhesive comprises a heat activated cure mechanism which is activated at a temperature of 90°C or more.

6. The method of claim 1 , further comprising providing one or more protuberances on the surface of the polymeric member, each protuberance of a predetermined height and extending from a base portion of the polymeric member toward the bonding surface of the glass substrate, the predetermined height of each protuberance corresponding to a desired thickness of the adhesive.

7. The method of claim 1 , wherein the adhesive separates the surface of the polymeric member from the bonding surface of the glass substrate and is disposed over the first primer.

8. The method of claim 1 , further comprising urging a portion of the ultrasonic bonding apparatus and the polymeric member toward the glass substrate so that the polymeric member is placed in an abutting relationship with the bonding surface of the glass substrate, wherein the polymeric member and bonding surface of the glass substrate are positioned relative to each other so that the adhesive is disposed over the bonding surface of the glass substrate and over the first primer.

9. The method of claim 1 , wherein the ultrasonic bonding apparatus comprises a horn which comprises a facing surface, the facing surface having a major aperture which receives an elongated portion of the polymeric member and a minor aperture which receives an anti-rotation protuberance of the polymeric member.

10. The method of claim 1 , wherein the ultrasonic bonding apparatus comprises a source of ultrasonic energy, the source of ultrasonic energy being in communication with a booster, the booster receiving ultrasonic energy from the source of ultrasonic energy and converting the ultrasonic energy into mechanical energy, wherein the booster communicates the mechanical energy to a horn, the horn receiving the polymeric member.

1 1 . The method of claim 2, wherein the adhesive is polyurethane based, the first primer comprises a silane coupling agent, and the second primer is polyurethane based.

12. The method of claim 5, wherein the heat activated cure mechanism is activated at a temperature of 90 - 180°C.

13. The method of claim 9, wherein the major aperture and the minor aperture are both in fluid communication with a source of vacuum.

14. The method of claim 10, wherein the booster communicates mechanical energy to the horn via a hollow, cylindrical arm.

15. An automotive window assembly made according to claim 1.