Thermo-Mechano-Electromagnetic Multi-Physics Coupling Analysis, Unified-Datum Tolerance Coordination and Full-Lifecycle Experimental Verification of Triple-Functional Integrated Automotive Laminated Windshield Glass

Abstract

Intelligent new-energy vehicles increasingly require front windshield laminated glass to integrate electrochromic dimming, low-temperature rapid defrosting and an embedded digital-television (DTV) antenna. The superposition of multilayer polymer films, screen-printed silver conductive traces and embedded flat wiring harnesses, however, introduces thermo-mechano-electromagnetic coupling failure modes. Here, we propose three hierarchically optimized substructures—a stepped-gradient ceramic anti-corrosion shielding layer, a 0.2 mm-protrusion full-wrap harness bonding configuration and full-wrap silicone sealing for marginal un-melted polyvinyl butyral (PVB) zones—and couple them with an ISO 5459-conformant unified symmetric datum (PD-A) tolerance chain model. A fully coupled thermo-mechano-electromagnetic finite-element numerical model, validated through a four-level mesh-convergence study and a five-factor parametric sensitivity matrix, is developed to quantify interfacial stress evolution and electromagnetic interference attenuation. A coupon-grade multi-station test fixture (denoted 8S10Z-39J-900) is fabricated and used for systematic cleavage peeling, alternating thermal cycling, hygrothermal/UV accelerated aging, optical modulation, electrothermal defrost and antenna electromagnetic tests. All quantitative results are reported as mean ± standard deviation of n = 6 parallel specimens and analyzed by one-way ANOVA followed by Tukey HSD post-hoc test at α = 0.05. The optimized harness scheme reduces the maximum interfacial shear stress from 18.46 ± 0.42 MPa to 10.58 ± 0.31 MPa (42.7 % reduction, p < 0.001), while the experimental average peeling force reaches 246.3 ± 4.8 N at 23 °C—23.1 % above the 200 N industrial threshold. After 1200 cycles of −30 °C↔+80 °C thermal cycling, 1000 h of 85 °C / 85 % RH hygrothermal exposure and 500 h of UV irradiation, no interlayer delamination or open-circuit failure is observed. Continuous transmittance is tunable within 12.3–77.8 %, full-band (470–860 MHz) DTV antenna gain fluctuation is bounded to ±1.3 dB (shielding effectiveness 11.4 dB at 470 MHz), and the dual-variant mass-production qualification rate over 42,716 inspected parts improves from 76.3 % to 99.2 %. To the authors’ knowledge, this work represents the first integrated thermo-mechano-electromagnetic numerical framework for triple-functional laminated windshield composite interfaces, supported by a self-developed unified-datum coupon-grade verification platform.