CN110831763A - 嵌入式电线led层压板 - Google Patents

嵌入式电线led层压板 Download PDF

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Publication number
CN110831763A
CN110831763A CN201880044401.3A CN201880044401A CN110831763A CN 110831763 A CN110831763 A CN 110831763A CN 201880044401 A CN201880044401 A CN 201880044401A CN 110831763 A CN110831763 A CN 110831763A
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laminate
glass
layer
leds
plastic
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CN110831763B (zh
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马里奥.阿图罗.曼海姆.阿斯塔特
贡萨洛.拉斐尔.维斯卡拉.门多萨
迪亚哥.阿隆索.瓦尔加斯.杜哈特
查尔斯.斯蒂芬.弗尔策尔
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AGP America SA
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AGP America SA
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    • B32B17/10165—Functional features of the laminated safety glass or glazing
    • B32B17/10541—Functional features of the laminated safety glass or glazing comprising a light source or a light guide
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Abstract

LED照明的价格和性能已经可以逐步取代传统照明。即使LED的使用寿命高达50,000小时，仍将它们设计为可替换的灯泡，而不是集成为照明组件的永久部件。本发明涉及一种经济可行、具有集成LED照明的夹层玻璃装置，根据设计，该集成LED照明可延长车辆的使用寿命。这是通过将LED模嵌入用于将层压板的玻璃层粘合在一起的塑料层中，由高强度的细钨丝形成嵌入式线路为LED供电，并利用最初开发的机床技术来制造集成电路组件，例如RFID ID卡、票证和护照。

Description

嵌入式电线LED层压板
技术领域
本发明涉及汽车层压板领域。
背景技术
尽管发光二极管(LED)已经商用了50多年，但直到最近几年，它的成本、尺寸、颜色、光强度和寿命才有所提高，可以与白炽灯等其他照明方式媲美。事实上，家庭和商业照明用的LED灯泡在节能方面的投资回报期相对较短，而大多数人都将从中受益。大多数情况下，LED灯泡的安装要能够兼容最初根据白炽灯设计的照明设备。具有讽刺意味的是，这些最先进的照明设备大多使用爱迪生螺杆式的螺纹底座，这与1909年首次引入时基本相同。
这种螺旋型灯座非常合适，因为早期的碳丝白炽灯的寿命是以小时为单位计算的。虽然这些年来技术已经有了很大的改进，但现代钨丝灯泡的使用寿命在500-2000小时范围内，所以在为白炽灯泡设计的照明设备中，使用可更换的灯泡仍有意义。
在汽车应用中，由于极端的温度、冲击和振动，白炽灯泡比静态的室内安装更易出现问题。在汽车应用中，LED具有一个主要的优势——它们不太容易受到极端温度、冲击和振动的影响。一个重要的附加好处是，与白炽灯泡相比，LED可以在更短的时间内达到全亮度。虽然差异只有几分之一秒，但在高速度行驶的车辆中，它是生与死的差异。用于汽车信号灯和车厢照明的LED替换灯泡已有数年的历史。许多早期适配器愿意支付额外的费用，将白炽灯泡换成LED灯泡。早期的原厂商(OEM)的汽车应用中，刹车灯的上升速度越快，安全性越高。如今，我们发现几乎所有传统汽车照明位置(包括头灯)都在使用LED照明。LED照明在电池驱动的汽车上尤其有价值，因为在电池驱动的汽车上，更高的效率和更低的重量可以转化为更大的行驶里程。
当前生产的LED的估计寿命高达50,000小时。与白炽灯泡不同的是，LED寿命终止不是当灯泡停止发光，而是当光的强度下降到原来的70％。在汽车的典型使用寿命中，LED在大多数应用中都比汽车寿命长。然而，尽管灯泡的寿命会比汽车长，灯泡的制造过程中仍然采用了与前代灯泡相同的可更换底座和插座设计。
随着其他汽车零部件的质量和耐用性的提高，在设计和制造上我们看到了一些调整，以配合寿命的延长。传动轴、控制臂和其他总成的制造通常使得组成总成的各个部件不可更换。当其中一个部件发生故障时，必须替换整个组件。这有助于减少装配的初始成本和重量，以及减少零件数量。
已经尝试将LED照明作为其他组件的一个不可分割的固定部分。一种常见的方法是将LED添加到夹层玻璃中。夹层玻璃是通过热塑性粘合层将两块玻璃粘合在一起而制成的。所有挡风玻璃均由夹层玻璃制成。夹层玻璃有时也用于门窗、背板、天窗和全景顶篷。
用于大多数汽车层压板粘结层的厚度为0.76毫米(30密耳)。实际的LED模更薄，因此可以被纳入粘合层。与这项技术商业化相关的问题主要是为LED芯片提供电源。
一种方法是在玻璃上使用透明导电涂层(TCO)来供电。这种方法需要对TCO进行蚀刻以形成电路，这比较困难且造价较高，因为它需要在涂层之前进行掩蔽或使用大型场激光器。大多数TCOs的导电性相对较差，这也使它成为除了少数LED之外的备选，同时也对它们的位置提出了限制。TCO方法的另一个问题是，很难建立到TCO可靠的、永久性电气连接。
类似的方法是将TCO应用于塑料基板。这改进了工艺，因为塑料基板比玻璃板更容易蚀刻或掩膜和涂覆。与TCO的关系仍然存在一些问题。塑料基材的引入要求在层板上增加第二层热塑性粘接层，导致成本和重量上升。此外，可以以这种方式分层的形状有限。可以制作大半径的圆柱形层合板，但任何需要拉伸基板的形状都会破坏电路的连续性。
另一种类似的方法是利用传统的轨迹提供能量，生产并层压一种灵活的透明印刷电路。这种方法在层压板的形状方面与TCO涂层衬底具有相同的缺点，并且将电路的大小限制在用于制造电路的设备的能力范围之内。这种方法只适用于可视导体不存在异议的情况。
由于成本高和产品外观差，试图通过使用细线在层压材料中为LED供电的尝试未能取得商业上的成功。导致问题的部分原因似乎是组装方法，由于现有技术未能完全实现组装方式而难以评估，所以很难进行判断。
显然，解决这些问题是有利的。
发明内容
本发明涉及层压在车辆玻璃内部的LED。面向室内照射的LED灯被用来提供室内照明，取代了典型的圆顶灯和阅读灯，并提供了其他可能不实际的照明应用。光源朝向外部辐射，提供主要信号，如高挂的刹车灯和辅助的刹车/转弯信号灯。这些灯藏在玻璃后面，不打开时几乎看不见。
此外，本发明还使用CNC(计算机数控)机器技术来生产一层含有LED 28的热塑性塑料，该热塑性塑料随后被夹在两个玻璃层之间。CNC要求工具在上/下、左/右和前进/后退方向(X，Y和Z)，以及垂直于床身的旋转轴和工具更换器以及嵌入电线16的工具中移动。切断电线16，放置LED芯片，然后将LED芯片连接到电线16。具有该功能的机器可在市场上买到。
例如，其中一些机器是在欧洲和亚洲制造的，用于生产嵌入线天线的产品和RFID(射频识别)应用的电子产品，如护照、身份证和入场券。此外，数控机床从卷轴上取下LED芯片，然后把它们放在塑料板上。通过机器底座上的真空孔将金属板压平，并固定在适当的位置。
在放置好LED 28之后，更换工具并分发连接LED 28的导线16，形成为LED供电的电路。所用的导线16是一种细的、黑色的、拉制的、实心的、不绝缘的钨丝，与制造白炽灯的钨丝相同。通过使用热量和压力，导线16基本上嵌入在塑料粘合层4中。超声也可以与压力结合使用，来嵌入导线16。导线16可以用机械方法切割，也可以用激光切割。通过使用激光，可以将整个电路的导线16作为一个连续的长度，并且可以节省所有切割时间。
特别是，由于其相对较高的电阻率，选择钨制的电力线路可能会出现反向的效果。但是，钨的电阻率是铜的三倍，而抗拉强度却是铜的十二倍。较高的强度使导线16能以更快的速度嵌入，并能更好地承受组装过程中的搬运，从而降低断裂的可能性。导线16通过导电粘合剂、压接、焊接、软焊或其他合适的方式电连接至LED 28。即使钨灯具有较高的电阻，由于LED的低功率要求，仍可以使用非常细的导线16。
另一方面，柔性连接器12用于与导线16进行电连接，并将连接从层压板内部引出。因此，导线16可以在柔性连接器12处终止。
另外，触控传感器14也可以可选地嵌入塑料粘合层4中。光扩散器30可以通过处理玻璃表面或应用到玻璃上来产生。同样，也可以在发光二极管后面添加反射器34。薄塑料透镜可层压在玻璃窗内部或应用于层压板的外部。而且，遮光6(例如，黑色玻璃料)可以具有开口或孔口8，这些开口或孔口8可以用于框住LED 28，并根据需要遮挡来自相反侧的视线。如果需要，可以使用透明导电涂层18或透明导电涂层的性能膜，来防止触控传感器14从层压板的另一侧(雨水)触发。为增强LED的美观性，可变的透光性能膜也可以包括在层压物中。层压板可用于车辆的任何玻璃位置。LED 28可用于车辆内外的照明、信号和一般美学应用。可使用深色玻璃组合物、性能薄膜、塑料层或涂层来减少通过层压材料的可见光透射，从而进一步隐藏导线16。
本发明的层压板及其方法的一些优点如下：
·节能；
·减轻重量；
·减少零件数量；
·降低成本；
·减少最终组装劳动力；和
·产品差异化。
附图说明
图1所示为带有室内照明的全景顶篷。
图2所示为带有外部信号照明的全景顶篷。
图3所示为典型的夹层玻璃横截面。
图4所示为一个具有五个串联LED的电路。
图5所示为一个具有五个串联的LED和触敏传感器的电路。
图6所示为带有扩散器的层压板在四号表面和两个塑料层上的截面。
图7所示为一段层压板与扩散器位于三号表面。
图8所示为涂覆在二号表面和2个塑料层上的层压板的截面。
图9所示为涂覆在二号表面的玻璃层上的层压板的截面。
图10所示为在第四号表面上有透镜、在第二号表面上有反射器的层压板的截面。
图11所示为在两个塑料层之间有性能薄膜的层压板的部分。
图12A所示为由带有反射器和扩散器的层压LED组成的层压板的分解图。
图12B所示为一个顶视图，其中包括带有反射器和扩散器的层压LED。
参考数字：
2 玻璃
4 塑料粘合夹层
6 遮光
8 孔
12 柔性连接器
14 触摸传感器
16 导线
18 透明导电涂料
28 LED
30 扩散器
32 镜片
34 反射器
36 性能膜
101 一号表面
102 二号表面
103 三号表面
104 四号表面
201 外部玻璃层
202 内部玻璃层
具体实施方式
本发明旨在提供一种夹层玻璃组件，该组件包括至少一个LED 28、相关的布线16、触摸传感器14和连接器12以及其制造方法。
本发明的层压板特指用于车辆应用，但应该理解，其他应用也可以使用，譬如建筑。本发明的层压板包括：
a.外部玻璃层201，其有一号表面101位于车辆外部，以及一个相反的二号表面102；
b.至少有一个内层玻璃层202，其有四号表面104位于车辆内部，以及有三号表面103；
c.至少一个塑料粘结层4位于外部玻璃层201和内部玻璃层202之间，其中塑料粘结层4将外部玻璃层201的二号表面102与内部玻璃层202的一号表面101相结合；
d.至少一个LED 28嵌入到塑料粘结层4中；和
e.实质上，嵌入到塑料粘合层4中的导线16形成了一个为LED供电的电路。
虽然所述的实施例和示例是全景顶篷层压板，但正如所理解的那样，本发明可以在车辆的任何其他玻璃位置实施，并不偏离本发明的意图。
特别地，在本文件的上下文中，玻璃装配是指任何通过任何汽车安全玻璃管理标准认证的安全玻璃。层压安全玻璃是由两片退火后的玻璃2用透明塑料粘合层4粘合在一起制成的，如图3所示。
退火玻璃是一种从弯曲温度缓慢冷却到玻璃转变范围的玻璃。这一过程消除了玻璃在弯曲过程中产生的应力。退火后的玻璃破碎成带有锋利边缘的大碎片。当夹层玻璃破碎时，破碎的玻璃碎片被塑料层粘合在一起，类似拼图游戏的碎片，有助于保持玻璃的结构完整性。挡风玻璃破损的车辆仍然可以操作。在冲击方面，塑料层4也有助于防止在发生碰撞时乘员的渗透和物体从外部撞击层板。
此外，标准术语用于描述层压玻璃的配置，如图3所示。例如，一个普通的汽车挡风玻璃是由两层玻璃组成的，一层是外部玻璃201层，另一层是内部玻璃202层。车辆外部的玻璃表面被称为一号表面101或第一表面。玻璃201的外层的相对面是二号表面102或第二表面。车辆内部的玻璃表面称为四号表面104或第四表面。内部玻璃层202的相对面是三号表面103或第三表面。
特别地，玻璃层是用重力弯曲、压力弯曲或冷弯曲形成的。用于形成玻璃的重力弯曲、冷弯曲和压力弯曲的方法在本领域中众所周知，在在此不进行讨论。
例如，玻璃包括但不限于：各种典型的普通钠钙汽车玻璃以及铝矽酸盐、锂铝硅酸盐、硼硅、玻璃陶瓷和其他各种无机固体非晶态成分进行玻璃化转变和被归类为玻璃的，包括那些不透明的玻璃。
层压玻璃制品在彩绘金属板上的主要优点之一是，该层压制品可以通过使用红外反射涂层或薄膜来更有效地反射太阳能。即使没有红外反射层，玻璃也会比油漆表面反射更多的太阳能。玻璃是不良的热导体，它还有助于减缓太阳能向车厢的传递，而发射率超过0.9，它可以通过将热量从车内辐射到外部空气来冷却车辆。
特别是，红外反射涂层包括但不限于通过真空沉积应用的各种金属/介电层涂层，以及其他已知的通过热解、喷涂、CVD和dip应用的涂层。例如，红外反射膜可包括金属涂覆的基底，以及在红外中反射的有机基光学膜。
另一方面，塑料粘结层4具有粘结相邻各层主要面的重要功能。作为示例，外部玻璃层202的二号表面102通过塑料结合层4与相邻和下面的层101的表面(例如内部玻璃层202)结合。选择的材料是典型的透明塑料时，粘接到另一个玻璃层2。对于汽车使用，最常用的塑料粘结层4或中间层是聚乙烯醇丁基(PVB)。除了聚乙烯醇丁基、离子聚合物和乙烯醋酸乙烯(EVA)，就地浇铸(CIP)液体树脂和热塑性聚氨酯(TPU)也可以使用。
这种诸如黑色熔块的遮光6是一种由高温黑色颜料、磨细的玻璃以及有机载体和粘合剂混合而成的油墨。黑色玻璃原料遮光6通常用于丝网印刷或喷墨印刷，并用于汽车玻璃，以遮蔽内部装饰和用于安装车辆玻璃时使用的粘合剂。在玻璃弯曲之前先涂上用于遮盖的黑色玻璃遮光6。在弯曲过程中，玻璃粉会与玻璃表面融合在一起，从而形成持久的永久粘合。例如，可以使用像黑色玻璃原料这样的遮光6来提供灰色着色层，该着色层是通过在玻璃层2的二号表面202或顶棚层压件的三号表面203或四号表面204上印刷而形成的，该表面包括至少两个玻璃层。
在本发明的一些层压板中，LED 28以串联电路连接，允许施加14电压系统为LED28的功率串供电，其中每跨一级，电压将降到所需的适当水平。图4示出了串联的五个LED28的一种可能的圆形布置。该数目可以根据电路的要求而增加或减少。多个串联串可以并联连接到单组馈电线，或者可以直接终止于连接器12。
例如，图5示出了串联的五个LED 28，以及由两个不相交的线环组成的电容式触摸传感器14。此功能避免了增加机械开/关开关的必要。触摸传感器14在本技术中是已知的，可以在不偏离本发明的意图的情况下，以其他任何方式实现。根据触摸传感器14的位置、设计和类型，可能需要一个金属屏蔽，以防止对面的介质(水)对触摸传感器14的干扰。为实现该目的，可使用透明导电涂层18，以及改善玻璃的日光性能。
此外，所有的LED 28都可以在一个单独的连接器12上终止。另外，可以使用多个连接器12。选择将取决于设计者和所做的权衡。较长的引线需要较大直径的导线来输送电流。譬如，柔性连接器12的厚度要小于0.6毫米。
另一方面，所示的各种示例性实施例都是用于四门轿车的大型全景夹层玻璃车顶的所有变体，如图1和图2的等轴测图所示。在图1中，LED 28的位置与照明灯的位置相同。芯片的发光面朝向车辆内部，并提供内部照明。常规的位于中心的圆顶灯由一组LED灯代替，驾驶员和前排乘客阅读灯也是如此。
同样，在每个门的上方都提供了额外的照明，以帮助车辆进出，并且还提供了一组后排乘客阅读灯。在图2中，LED 28布置时，芯片的发光侧面向车辆的外部。LED28是用来发出信号的，高处的停止灯在后面，每个角落有四个转向辅助指示灯。
根据电路的复杂性，导线16的直径以及LED的厚度和数量，如一些实施例中所示，可能需要第二层塑料粘结层4。例如，导线16的直径可以在大约18μm和大约200μm之间。
另外，由于增加的成本和重量，优选仅使用一个塑料粘结层4。而且，使导线16和LED 28与玻璃直接接触后可以进行更好的热传递和散热。尽管LED 28非常高效，但是它们仍然会产生一些热量。
例如，LED 28的分布应使功率密度不超过每平方分米10瓦。
此外，可以通过玻璃的表面处理、涂覆在玻璃表面的涂层或粘接在玻璃上的组件来添加光扩散器30，如图12A和12B所示。同样，可以通过表面处理、涂层或部件来添加反射器34。对于某些类型的照明，可能需要透镜32来聚光。可以在塑料粘合层4附近层压平坦的菲涅耳型透镜32，或者可以在层压板的外表面或内表面上将菲涅耳或其他类型的透镜32粘合到玻璃表面。
另一方面，已经发现，深色塑料粘合层4，特别是与深色玻璃组合物一起，有助于隐藏嵌入的导线16。例如，所描述的实施例全部具有小于5％的总可见光透射率，但是应当理解，根据需要，塑料粘结层4可以具有不同的可见光透射率值，例如可以小于20％。
另外，在层压板中，至少一个玻璃层是外部玻璃层201或内部玻璃层202，并且在许多情况下，两个玻璃层201、202通常都将进行黑色遮光，以隐藏任何另一侧起的粘合剂或附接物，并且还可以遮蔽集成到层压件中的涂层或膜的边缘。
例如，可以使用黑色玻璃原料或等效的遮光6覆盖LED，以防止通过层压板从预期光路相反的一侧看到。如图12A和12B所示，它也可以被图案化设计为具有黑色遮光的孔8，以框住并改善LED照明的美感。
实施例1：
图6示出了全景顶篷的横截面，该全景顶篷包括两个2.1毫米的深色吸热玻璃层2，这些玻璃层压有0.76毫米的灰色着色PVB的塑料粘合层4和0.38毫米的透明PVB的塑料粘合层4。导线16和LED 28嵌入在0.76毫米的塑料结合层4PVB层中。将塑料光漫射器30结合到层压板内侧上的四号玻璃表面104。层压板还包含嵌入式电线触摸传感器14。
实施例2：
图7所示为由含有灰色着色PVB的单层0.76毫米塑料的粘接层4和两层2.1毫米暗吸热玻璃层2组成的全景车顶横截面。导线16和LED28嵌入在0.76毫米的PVB层中。塑料光漫射器30结合至三号表面103。层压板还包含嵌入式电线触摸传感器14。
实施例3：
图8示出了全景顶篷的横截面，该全景顶篷包括两个2.1毫米的深色吸热玻璃层2，这些玻璃层压有0.76毫米的灰色着色PVB的塑料粘合层4和0.38毫米的透明PVB的塑料粘合层4。电线16和LED 28嵌入在0.76毫米的塑料结合层4中。将TCO红外反射涂层18覆盖在玻璃的两个表面102上。层压板还包含嵌入式电线触摸传感器14。
实施例4：
图9所示为由含有灰色着色PVB的单层0.76毫米塑料的粘接层4和两层2.1毫米暗吸热玻璃层2组成的全景车顶横截面。将TCO红外反射涂层18覆盖在玻璃的两个表面102上。导线16和LED 28嵌入在0.76毫米的PVB层中。层压板还包含嵌入式电线触摸传感器14。
实施例5：
图10所示为由含有灰色着色PVB的单层0.76毫米塑料的粘接层4和两层2.1毫米暗吸热玻璃层2组成的全景车顶横截面。电线16和LED28嵌入在0.76毫米PVB塑料结合层4中。塑料反射器34结合到二号表面102中，塑料透镜32结合到四号表面104中。层压板还包含嵌入式电线触摸传感器14。
实施例6：
图11示出了全景顶篷的横截面，该全景顶篷包括两个2.1毫米的深色吸热玻璃层2，这些玻璃层压有0.76毫米的灰色着色PVB的塑料粘合层4和0.38毫米的透明PVB层。在两个PVB层之间层压有性能膜36。导线16和LED 28嵌入在0.76毫米的PVB层中。层压板还包含嵌入式电线触摸传感器14。
本规范中所示和描述的发明的形式代表了说明性的优选实施例，据了解，可以在不违背下列所述主题中定义的发明精神的情况下进行各种更改。

Claims (26)

1.一种车辆层压板，包括：
a)外部玻璃层；
b)至少一个内部玻璃层；
c)位于外部玻璃层和内部玻璃层之间的至少一个塑料粘结层；
d)至少一个LED嵌入塑料粘结层中；和
e)嵌入塑料粘结层中的导线形成为LED供电的电路。
2.根据权利要求1所述的层压板，其中金属丝材料是钨。
3.根据权利要求2所述的层压板，其中，所述线的直径在约18微米至约200微米之间。
4.根据权利要求2所述的层压板，其中导线端接柔性接头。
5.根据权利要求4所述的层压板，其中柔性连接器的厚度小于0.6毫米。
6.根据权利要求1所述的层压板，其中LED电路的功率密度小于每平方分米10瓦。
7.根据权利要求1所述的层压板进一步包括集成到层压板中的至少一个触摸传感器。
8.根据权利要求7所述的层压板，其中，所述触摸传感器由嵌入线构成。
9.根据权利要求7所述的层压板，进一步包括将所述触摸传感器与所述层压板的外部隔离的透明导电涂层。
10.根据权利要求1所述的层压板，其中总的可见光透射率小于约20％。
11.根据权利要求1所述的层压板，其中总的可见光透射率小于约10％。
12.根据权利要求1所述的层压板，其中总的可见光透射率小于约5％。
13.根据权利要求1所述的层压板，其中，所述层压板包括具有孔的遮光，其中，所述LED位于所述孔中。
14.根据权利要求13所述的层压板，其中，所述遮光位于所述LED上方，以便隐藏所述LED。
15.根据权利要求1所述的层压板进一步包括位于玻璃层之间的至少一个光扩散器。
16.根据权利要求1所述的层压板，进一步包括至少一个导光透镜，其中导光透镜在该层压板的外表面或内表面与塑料粘合层相邻或与玻璃表面粘合。
17.根据权利要求1所述的层压板进一步包括至少一个光反射器，其中光反射器连接到外部玻璃层第二表面，或通过表面处理、涂层或组件添加。
18.根据权利要求1所述的层压板进一步包括应用于第二表面的抗反射涂层。
19.根据权利要求1所述的层压板，其中数控机床用于制造嵌入式线路。
20.根据权利要求1所述的层压板，其中激光用于切割嵌入的电线。
21.根据权利要求1所述的层压板进一步包括连接到第一粘合层的第二粘合层。
22.根据权利要求1所述的层压板，其中导线通过导电粘合剂、压接、焊接、软焊或其组合连接到LED。
23.一种包括权利要求1所述的层压板的车辆。
24.一种具有嵌入LED的层压板的制造方法，包括：
a)提供外部和内部玻璃层；
b)在玻璃层之间提供塑料粘结层；
c)将LED放置在塑料粘合层上；
c)在塑料粘结层中布线，并将导线连接到LED；
d)切断电线；和
e)将外部玻璃层与内部玻璃层层压在一起。
25.根据权利要求24所述的方法，其中通过使用热和压力，金属线实质上嵌入到塑料粘合层中；超声波或其组合。
26.根据权利要求24所述的方法，其中金属丝是用机械方法或激光在步骤d)中切割完成。
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