US20080272613A1 - Encapsulated plastic panel and method of making the same - Google Patents

Encapsulated plastic panel and method of making the same Download PDF

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Publication number
US20080272613A1
US20080272613A1 US12/113,656 US11365608A US2008272613A1 US 20080272613 A1 US20080272613 A1 US 20080272613A1 US 11365608 A US11365608 A US 11365608A US 2008272613 A1 US2008272613 A1 US 2008272613A1
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US
United States
Prior art keywords
plastic
panel
glazing panel
ink
plastic glazing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
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US12/113,656
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English (en)
Inventor
Keith D. Weiss
Steven M. Gasworth
Sunitha K. Grandhee
Wilfried Hedderich
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Exatec LLC
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Exatec LLC
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Application filed by Exatec LLC filed Critical Exatec LLC
Priority to US12/113,656 priority Critical patent/US20080272613A1/en
Assigned to EXATEC LLC reassignment EXATEC LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: WEISS, KEITH D., HEDDERICH, WILFRIED, GRANDHEE, SUNITHA K., GASWORTH, STEVEN M.
Publication of US20080272613A1 publication Critical patent/US20080272613A1/en
Priority to US14/467,133 priority patent/US9139242B2/en
Priority to US14/842,164 priority patent/US10052850B2/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14336—Coating a portion of the article, e.g. the edge of the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14811—Multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
    • B29C70/76—Moulding on edges or extremities of the preformed part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
    • B29C70/76—Moulding on edges or extremities of the preformed part
    • B29C70/763—Moulding on edges or extremities of the preformed part the edges being disposed in a substantial flat plane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B32B27/365—Layered products comprising a layer of synthetic resin comprising polyesters comprising polycarbonates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/14—Printing or colouring
    • B32B38/145—Printing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
    • B60J1/00—Windows; Windscreens; Accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
    • B60J1/00—Windows; Windscreens; Accessories therefor
    • B60J1/08—Windows; Windscreens; Accessories therefor arranged at vehicle sides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
    • B60J7/00—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D65/00—Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
    • B62D65/02—Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components
    • B62D65/06—Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components the sub-units or components being doors, windows, openable roofs, lids, bonnets, or weather strips or seals therefor
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D11/00—Inks
    • C09D11/02—Printing inks
    • C09D11/10—Printing inks based on artificial resins
    • C09D11/101—Inks specially adapted for printing processes involving curing by wave energy or particle radiation, e.g. with UV-curing following the printing
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D11/00—Inks
    • C09D11/02—Printing inks
    • C09D11/10—Printing inks based on artificial resins
    • C09D11/102—Printing inks based on artificial resins containing macromolecular compounds obtained by reactions other than those only involving unsaturated carbon-to-carbon bonds
    • C09D11/104—Polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2795/00—Printing on articles made from plastics or substances in a plastic state
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14336—Coating a portion of the article, e.g. the edge of the article
    • B29C45/14434—Coating brittle material, e.g. glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/002—Coloured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/0025—Opaque
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0087—Wear resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/778—Windows
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/20—Inorganic coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/28—Multiple coating on one surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/72—Cured, e.g. vulcanised, cross-linked
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
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    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2605/00—Vehicles
    • B32B2605/006—Transparent parts other than made from inorganic glass, e.g. polycarbonate glazings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23—Sheet including cover or casing
    • Y10T428/239—Complete cover or casing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24777—Edge feature

Definitions

  • This invention relates to plastic glazing panels that are encapsulated to promote sealing and appearance when used as a window or sunroof.
  • Such encapsulation technology includes molding an elastomeric gasket directly onto the surface of the glass.
  • gaskets are typically made from a variety of materials including thermoplastic elastomers (TPE) and polyvinyl chloride (PVC), as well as cross-linked polyurethanes applied via reaction injection molding (RIM).
  • the encapsulation process for a conventional glass window may be described as including the steps of applying a primer or adhesion promoter to the perimeter of the one side of the window; applying heat to this side of the window to activate the primer; placing the window in a mold; injecting the thermoplastic elastomer onto the primer and the adjacent surface of the window; removing the window from the mold, and trimming any excess elastomeric material that has accumulated at the interface between the window and the encapsulation.
  • Such excess or scrap elastomeric material is known by one skilled-in-the-art of encapsulation as “flash” material.
  • the trimming of the “flash” material is typically done with a sharp object, such as a knife or razor blade.
  • the encapsulated glass window is then fixed into the opening of a vehicle typically through the use of an adhesive system, such as the urethane BETASEALTM system offered by Dow Automotive, Auburn Hills, Mich.
  • plastic glazing panels provide several issues for the use of conventional encapsulation technology.
  • plastic glazing panels are typically coated with a weatherable coating system, such as the acrylic primer (e.g., SHP401 and SHP470) and silicone hard-coat (e.g., AS4000 and AS4700) systems offered by Momentive Performance Materials, Wilton, Conn. in order for the glazing panel to survive exposure to the environment.
  • a weatherable coating system such as the acrylic primer (e.g., SHP401 and SHP470) and silicone hard-coat (e.g., AS4000 and AS4700) systems offered by Momentive Performance Materials, Wilton, Conn.
  • the surface properties associated with a silicone hard-coat is such that most conventional encapsulation materials can not effectively adhere, thereby, creating a weakened interface that will cause the plastic glazing after being fixed to a vehicle to prematurely fail.
  • the known remedy for this situation has been to apply the encapsulation to the bare plastic panel (e.g., no protective coatings).
  • this solution requires a
  • plastic glazing systems are not as hard as a conventional glass window.
  • trimming of any “flash” material created by the encapsulation process will result in irreversible damage to the coating system of the plastic glazing panel. This damage will ultimately result in premature degradation of the properties exhibited by the plastic glazing panel.
  • plastic glazing panels exhibit different thermal expansion characteristics than glass windows.
  • heating the surface of the plastic glazing panel to activate any adhesion promoter used to facilitate adhesion between the plastic glazing panel and the encapsulation will cause substantial distortion to the shape of the window.
  • Such a distortion will result in the operator having difficulty in securing the window into the mold during the encapsulation process.
  • this process will suffer from an increase in cycle time and an overall loss in productivity.
  • This economical method includes the steps of forming a plastic panel having an A-side and B-side; printing an opaque border from an ink with the border being in contact with the B-side of the panel and substantially encircling the perimeter of the panel; curing the ink of the opaque border; applying a weatherable layer on the printed border and the plastic panel; curing the weatherable layer; depositing an abrasion resistant layer on the weatherable layer; placing the plastic panel into a mold having a soft gasket; injecting an elastomeric material to form an encapsulation that substantially encircles the perimeter of the plastic panel and encompasses the A-side, B-side, and edge of the plastic panel; and finally removing the plastic panel from the mold.
  • the use of a soft gasket in the mold reduces or eliminates the occurrence of “flash” material being generated at the edge of the interface between the encapsulation and the plastic glazing
  • the step of applying an adhesion promoter on top of the abrasion resistant layer encircling the B-side perimeter of the plastic panel may take place prior to placing the plastic panel into the mold to form the encapsulation.
  • the plastic panel is then heated on the A-side and B-side of the plastic panel in close temporal proximity to activate the adhesion promoter without substantially distorting the shape of the window.
  • the steps of printing an opaque border from an ink and curing the ink on the plastic panel is replaced with the steps of printing an opaque border from an ink on to a plastic film; curing the ink on the plastic film; and forming and adhering the opaque border and the plastic film to the B-side of the plastic panel so that the opaque border substantially encircles the perimeter of the plastic panel.
  • the encapsulated plastic glazing panel comprises a substantially transparent plastic panel having an A-side, B-side, and an edge; an opaque border in contact with the B-side of the plastic panel and that substantially encircles the perimeter of the plastic panel; a weatherable layer in contact with the opaque border and the plastic panel; an abrasion resistant layer in contact with the weatherable layer; and an encapsulation in contact with the abrasion resistant layer and that substantially encircles the perimeter of the plastic panel and encompasses the A-side, B-side, and edge of the plastic panel.
  • the plastic glazing panel further comprises a plastic film that has one side of the film in contact with the opaque border and the B-side of the plastic panel and the other side of the film in contact with the weatherable layer.
  • the weatherable layer may include a single layer or multiple layers, such as a primer and a topcoat.
  • the weatherable layer uses ultraviolet absorbing (UVA) molecules to protect the plastic panel from UV radiation.
  • UVA ultraviolet absorbing
  • the abrasion resistant layer is deposited using a vacuum deposition technique.
  • an abrasion resistant layer includes, but is not limited to, silicon oxy-carbide having a composition ranging from SiO x to SiO x C y H z .
  • FIG. 1 is a depiction of an automobile window according to the principles of the present invention.
  • FIG. 2 is a schematic of a manufacturing process for a plastic glazing panel according to one embodiment of the present invention.
  • FIG. 3 is a diagrammatic representation of a cross-section of a glazing panel from FIG. 1 according to one embodiment of the present invention.
  • the present invention provides a plastic glazing panel and an economical method of manufacturing such a glazing panel that includes the application of encapsulation that substantially encircles the perimeter of the window.
  • the plastic glazing panel also includes a decorative printed border and a protective coating system to provide a high level of weatherability and abrasion resistance.
  • a plastic glazing panel may be used as an automotive fixed side window 10 .
  • the window 10 is shown having a substantially transparent viewing area 15 , a printed opaque border 20 encompassing the transparent viewing area 15 , and an encapsulation 25 encircling the perimeter of the glazing panel 10 .
  • One skilled-in-the-art of automotive design will realize that the plastic glazing panel of the present invention can be used for other automotive windows, such as a backlite, sunroof, and movable side windows, among others.
  • an economical manufacturing process may generally be defined by first forming 30 a plastic panel; then printing 35 an opaque border with an ink on the plastic panel; followed by curing 40 the printed ink; applying 45 a weatherable layer onto the printed plastic panel; curing 50 the weatherable layer, depositing 55 an abrasion resistant layer onto the weatherable layer, placing 60 the panel into a mold; forming 65 the encapsulation by injecting an encapsulating material to the outer perimeter of the glazing panel, and then removing 70 the encapsulated glazing panel from the mold.
  • the transparent plastic panel may be formed 30 into a window, e.g., vehicle window, from plastic pellets or sheets through the use of any known technique to those skilled in the art, such as extrusion, molding, which includes injection molding, blow molding, and compression molding, or thermoforming, which includes thermal forming, vacuum forming, and cold forming. It is to be noted that the forming 30 of a window using plastic sheet may occur prior to printing as shown in FIG. 2 , after printing 35 and curing 40 of the ink, or after application 45 and curing 50 of the weatherable coating without falling beyond the scope or spirit of the present invention. The use of plastic pellets to form 30 the plastic panel is done prior to printing 35 the opaque pattern.
  • An opaque border may be defined as a substantially opaque ink printed or applied 35 for decorative purposes and/or to hide or mask other vehicle components (e.g., adhesives). This opaque border may be applied 35 to the periphery of the transparent substrate to form a solid masking border.
  • the opaque border may further include a fade-out pattern to transition the border into the viewing region of the window.
  • the fade-out pattern may incorporate a variety of shapes of variable size including dots, rectangles (lines), squares, and triangles, among others.
  • the opaque border and can be printed 35 onto the surface of the plastic panel via screen printing.
  • Other known methods of printing 35 the opaque border on the plastic panel may also be utilized when deemed appropriate.
  • a non-inclusive list of other known printing methods include pad printing, membrane image transfer printing, cylindrical printing, digital printing, robotic dispensing, mask/spray, ink-jet printing, and the like.
  • the thickness of the printed ink may range from about 2 micrometers to about 1 mil (25.4 micrometers) with about 6 to 12 micrometers being preferred.
  • the inks may be thermally cured by being exposed to an elevated temperature for a period of time, cured upon exposure to UV radiation, or via a combination thereof.
  • the thickness of the cured ink print is typically about 4 ⁇ m to 20 ⁇ m with between about 6 ⁇ m to 18 ⁇ m being preferred.
  • the weatherable layer is applied 45 to the printed panel by dip coating, flow coating, spray coating, curtain coating, spin coating, or any other techniques known to those skilled-in-the-art.
  • the weatherable layer may then be cured 50 using a mechanism selected as one of air drying, UV absorption, thermal absorption, condensation addition, thermally driven entanglement, cross-linking induced by cationic or anionic species, or a combination thereof.
  • the weatherable layer is over-coated via the deposition 55 of an abrasion resistant layer.
  • This abrasion resistant layer may be either comprised of one layer or a combination of multiple inter-layers of variable composition.
  • the abrasion resistant layer is applied by any vacuum deposition technique known to those skilled-in-the-art, including but not limited to plasma-enhanced chemical vapor deposition (PECVD), expanding thermal plasma PECVD, plasma polymerization, photochemical vapor deposition, ion beam deposition, ion plating deposition, cathodic arc deposition, sputtering, evaporation, hollow-cathode activated deposition, magnetron activated deposition, activated reactive evaporation, thermal chemical vapor deposition, and any known sol-gel coating process.
  • PECVD plasma-enhanced chemical vapor deposition
  • expanding thermal plasma PECVD plasma polymerization
  • photochemical vapor deposition ion beam deposition
  • ion plating deposition catho
  • a specific type of PECVD process used to deposit the abrasion resistant layers comprising an expanding thermal plasma reactor is preferred.
  • This specific process (called hereafter as an expanding thermal plasma PECVD process) is described in detail in U.S. patent application Ser. No. 10/881,949 (filed Jun. 28, 2004) and U.S. patent application Ser. No. 11/075,343 (filed Mar. 8, 2005), the entirety of both being hereby incorporated by reference.
  • a plasma is generated via applying a direct-current (DC) voltage to a cathode that arcs to a corresponding anode plate in an inert gas environment.
  • DC direct-current
  • the pressure near the cathode is typically higher than about 150 Torr, e.g., close to atmospheric pressure, while the pressure near the anode resembles the process pressure established in the plasma treatment chamber of about 20 mTorr to about 100 mTorr.
  • the near atmospheric thermal plasma then supersonically expands into the plasma treatment chamber.
  • the reactive reagent for the expanding thermal plasma PECVD process may comprise, for example, octamethylcyclotetrasiloxane (D4), tetramethyldisiloxane (TMDSO), hexamethyldisiloxane (HMDSO), vinyl-D4 or another volatile organosilicon compound.
  • the organosilicon compounds are oxidized, decomposed, and polymerized in the arc plasma deposition equipment, typically in the presence of oxygen and an inert carrier gas, such as argon, to form an abrasion resistant layer.
  • the plastic glazing panel is then placed 60 into a mold whose cavity is formed to the shape of the glazing panel.
  • the mold is equipped with a soft gasket to seal the substantially transparent viewing portion of the glazing panel from the subsequent injection of the encapsulation material that forms 65 the encapsulation.
  • the gasket provides an effective stop to the flow of the encapsulation material, thereby, eliminating the formation of any “flash” material at the edge of the interface between the encapsulation and the glazing panel.
  • the existence of “flash” material is found to cause the formation of wrinkles or blemishes in the abrasion resistant layer of the plastic glazing.
  • the trimming or removal of “flash” material via the use of a sharp instrument can damage the abrasion resistant layer and the weatherable layer of the plastic glazing panel, as well as possibly the opaque border and the underlying plastic panel itself.
  • an adhesion promoter may optionally be used to enhance adhesion between the abrasion resistant layer and the encapsulation.
  • the conventional means of applying and curing or activating the primer is unacceptable for use with a plastic glazing system.
  • the thermal expansion characteristics of a plastic glazing panel are such that applying heat onto one surface of the plastic panel results in reversible expansion or distortion of the shape of the panel. This expansion or distortion results in difficulty in holding the glazing panel by any mechanical means (e.g., robotic, etc.) and in placing 60 the glazing panel into the mold.
  • the application of heat on both surfaces of the glazing panel via substantially simultaneous application is found to minimize or eliminate the occurrence of this distortion.
  • the application of heat to both sides of the window may be accomplished through the use of any means known to one skilled-in-the-art, including, but not limited to, IR heating or forced air heating.
  • the plastic panel 15 may be comprised of any thermoplastic or thermoset polymeric resin.
  • the polymeric resins include, but are not limited to, polycarbonate, acrylic, polyarylate, polyester, and polysulfone, as well as copolymers and mixtures thereof.
  • the plastic panel 15 is substantially transparent.
  • the printed ink 20 may be comprised of a thermally curable ink or a UV curable ink.
  • a thermally curable ink may include a polyester-based binder, a polycarbonate-based binder, or a mixture thereof.
  • a UV curable ink may include a mixture of various multifunctional acrylate oligomers and monomers along with a photoinitiator. Examples of inks include Exatec® PIX (Exatec LLC, Wixom, Mich.) and DXT-1599 (Coates Screen, St. Charles, Ill.), among others.
  • the ink 20 may further comprise other additives, such as colorants (e.g., pigments and/or dyes), fillers, surfactants, defoamers, tackifiers, adhesion promoters, viscosity promoters, weatherability additives.
  • colorants e.g., pigments and/or dyes
  • fillers e.g., surfactants, defoamers, tackifiers, adhesion promoters, viscosity promoters, weatherability additives.
  • surfactants and defoamers may include any organic, organosilicon, and silicone molecules that are well known to one skilled-in-the-art to function in such a capacity.
  • the ink may include hindered amines or UV absorber molecules.
  • the weatherable layer 75 may be comprised of, but not limited to, silicones, polyurethanes, acrylics, polyesters, polyurethane-acrylates, and epoxies, as well as mixtures or copolymers thereof.
  • the weatherable layer 75 preferably includes ultraviolet (UV) absorbing molecules, such as hydroxyphenyltriazine, hydroxybenzophenones, hydroxylphenylbenzotriazoles, hydroxyphenyltriazines, polyaroylresorcinols, 2-(3-triethoxysilylpropyl)-4,6-dibenzoylresorcinol) (SDBR), 4,6-dibenzoylresorcinol (DBR), and cyanoacrylates, among others to protect the underlying plastic panel and printed ink from degradation caused by exposure to the outdoor environment.
  • UV ultraviolet
  • the weatherable layer 75 may be comprised of one homogenous layer or multiple sub-layers, such as a primer and a topcoat.
  • a primer typically aids in adhering the topcoat to the plastic panel.
  • the primer for example may include, but not be limited to, acrylics, polyesters, epoxies, and copolymers and mixtures thereof.
  • the topcoat may include, but not be limited to, polymethylmethacrylate, polyvinylidene fluoride, polyvinylfluoride, polypropylene, polyethylene, polyurethane, silicone, polymethacrylate, polyurethane-acrylates, polyacrylate, polyvinylidene fluoride, silicone hardcoat, and mixtures or copolymers thereof.
  • a weatherable layer 75 comprising multiple sub-layers is the combination of an acrylic primer (SHP401 or SHP470, Momentive Performance Materials, Waterford, N.Y.; or SHP-9X, Exatec LLC, Wixom, Mich.) with a silicone hard-coat (AS4000 or AS4700, Momentive Performance Materials; or SHX, Exatec LLC).
  • an acrylic primer SHP401 or SHP470, Momentive Performance Materials, Waterford, N.Y.
  • SHP-9X Exatec LLC, Wixom, Mich.
  • AS4000 or AS4700 Momentive Performance Materials
  • SHX Exatec LLC
  • a variety of additives may be added to the weatherable layer 75 , e.g., to either or both the primer and the topcoat, such as colorants (tints), Theological control agents, mold release agents, antioxidants, and IR absorbing or reflecting pigments, among others.
  • colorants such as colorants (tints), Theological control agents, mold release agents, antioxidants, and IR absorbing or reflecting pigments, among others.
  • the type of additive and the amount of each additive is determined by the performance required by the plastic glazing panel to meet the specification and requirements for use as a window.
  • the abrasion resistant layer 80 may be comprised of aluminum oxide, barium fluoride, boron nitride, hafnium oxide, lanthanum fluoride, magnesium fluoride, magnesium oxide, scandium oxide, silicon monoxide, silicon dioxide, silicon nitride, silicon oxy-nitride, silicon oxy-carbide, hydrogenated silicon oxy-carbide, silicon carbide, tantalum oxide, titanium oxide, tin oxide, indium tin oxide, yttrium oxide, zinc oxide, zinc selenide, zinc sulfide, zirconium oxide, zirconium titanate, or a mixture or blend thereof.
  • the abrasion resistant layer 80 is comprised of a composition ranging from SiO x to SiO x C y H z depending upon the amount of carbon and hydrogen atoms that remain in the deposited layer.
  • This preferred silicon oxy-carbide layer provides the surface properties suitable for the subsequent adherence of an encapsulation material.
  • the encapsulation 25 may be comprised of any known encapsulation material known to one skilled-in-the-art including, but not limited to, polyvinyl chloride (PVC), thermoplastic elastomers, urethanes, and thermoplastic olefins.
  • PVC polyvinyl chloride
  • thermoplastic elastomers thermoplastic elastomers
  • urethanes thermoplastic olefins
  • an adhesion promoter 85 may be used to enhance the adhesion between the encapsulation and the abrasion resistant layer.
  • adhesion promoters include acrylic polymers, urethanes, organosilanes, and chlorinated polyolefin polymers, among others.
  • the encapsulated glazing panel may be fixed or secured to an opening in a vehicle through any means known to one skilled-in-the-art. Such means include, but are not limited to, the use of clips or fasteners and bonding via the use of adhesives.
  • the glazing panel Before an encapsulated glazing panel can be used on a vehicle, the glazing panel must pass a series of tests specified by the original equipment manufacturers (OEMs) to be done using either the finished, encapsulated plastic glazing panels or smaller test plaques or coupons that represent the encapsulated glazing panel.
  • OEMs original equipment manufacturers
  • One very demanding series of tests used with coupons is specified by Nissan Motor Company as specification number N/K.
  • N/K the number of tests used with coupons.
  • coupons of the encapsulated glazing system are exposed to various conditions and then the encapsulation is pulled away from the plastic glazing panel under both shear and peel loads.
  • the failure mode observed upon separation of the encapsulation from the glazing panel must be 100% cohesive failure of the encapsulation.
  • any loss of adhesion at any interface within the plastic glazing panel e.g., between the plastic panel and the ink, the ink and weatherable layer, or weatherable layer and abrasion resistant layer
  • any loss of adhesion at any interface within the plastic glazing panel e.g., between the plastic panel and the ink, the ink and weatherable layer, or weatherable layer and abrasion resistant layer
  • between the glazing panel and the encapsulation would constitute a failure.
  • Lexan® polycarbonate sheet SABIC Innovative Plastics, Pittsfield, Mass.
  • the formed plastic panel was printed with an opaque border using a thermally curable ink (Exatec® PIX, Exatec LLC, Wixom, Mich.), which was subsequently cured according to the manufacturer's specification.
  • a weatherable layer comprised of an acrylic primer (SHP401, Momentive Performance Materials, Waterford, N.Y.) and a silicon hard-coat (SHX, Exatec LLC) was applied over the opaque border and plastic panel.
  • a silicon oxy-carbide abrasion resistant layer was deposited using expanding arc plasma enhanced chemical vapor deposition.
  • the resulting plastic glazing panel is known as the Exatec® 500 glazing system (Exatec LLC, Wixom, Mich.).
  • An adhesion promoter was then applied around the perimeter of the glazing panel in-line with the opaque border.
  • the adhesion promoter was cured or activated by simultaneously heating both sides of the glazing panel using an IR heating source.
  • the glazing panel was placed into a mold and polyvinyl chloride (Vi-Chem Corporation, Grand Rapids, Mich.) injected to form the encapsulation.
  • plastic glazing coupons were formed using Lexan® polycarbonate sheet (SABIC Innovative Plastics, Pittsfield, Mass.) to be substantially flat.
  • the formed plastic coupons were printed with an opaque border using a thermally curable ink (Exatec® PIX, Exatec LLC, Wixom, Mich.), which was subsequently cured according to the manufacturer's specification.
  • a weatherable layer comprised of an acrylic primer (SHP401, Momentive Performance Materials, Waterford, N.Y.) and a silicon hard-coat (SHX, Exatec LLC) was applied over the each opaque border and plastic coupon.
  • a silicon oxy-carbide abrasion resistant layer was deposited using expanding arc plasma enhanced chemical vapor deposition.
  • the resulting plastic glazing coupons represented a glazing system known as the Exatec® 500 glazing system (Exatec LLC, Wixom, Mich.).
  • plastic glazing panels were formed using Lexan® polycarbonate sheet (SABIC Innovative Plastics, Pittsfield, Mass.) into a substantially flat panel.
  • the formed plastic panel was printed with an opaque border using a thermally curable ink (Exatec® PIX, Exatec LLC, Wixom, Mich.), which was subsequently cured according to the manufacturer's specification.
  • a weatherable layer comprised of an acrylic primer (SHP-9 ⁇ , Exatec LLC, Wixom, Mich.) and a silicon hard-coat (SHX, Exatec LLC) was applied over the opaque border and plastic panel.
  • a silicon oxy-carbide abrasion resistant layer was deposited using expanding arc plasma enhanced chemical vapor deposition.
  • the resulting plastic glazing panel is known as the Exatec® 900 glazing system (Exatec LLC, Wixom, Mich.).
  • the glazing panels having the outer layer as the weatherable layer is representative of the situation of the outer surface being a silicon hard-coat.
  • Adhesion promoters and a urethane adhesive bead was applied to the perimeter of the glazing panels having a silicon hard-coat surface and the glazing panels having an outer surface of an abrasion resistant layer.
  • the adhesion promoters and urethane adhesive is known as the BETASEALTM system offered by Dow Automotive, Auburn Hills, Mich.
  • the adhesion promoters and urethane adhesive was cured according to the manufacturer's specification.
  • the glazing panels were then subjected to a Cataplasma test known to one skilled-in-the-art as Dow Automotive AG, Test Method No. 039E—Cataplasma Treatment.
  • the Cataplasma test is also incorporated as one of the tests performed in the Hyundai Motor Company N/K test specification.
  • the Cataplasma test exposes the plastic glazing panel along with cured adhesive beads applied to the surface of the glazing panel to high humidity at an elevated temperature followed by a low temperature shock (i.e., wrapping the glazing panel for 7 days in wet cotton at 70° C. followed by 3 hrs at ⁇ 20° C.).
  • the adhesive bead is pulled on each test panel and the degree of cohesive failure of the adhesive is examined.
  • room temperature about 23° C.
  • the entire glazing panel i.e., plastic panel 15 /cured ink 20 /cured weatherable layer 75 /abrasion resistant layer 80 (if present) must exhibit a high level of hydrolytic stability at different temperatures and moisture conditions.
US12/113,656 2007-05-01 2008-05-01 Encapsulated plastic panel and method of making the same Abandoned US20080272613A1 (en)

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ATE541002T1 (de) 2012-01-15
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US20140367028A1 (en) 2014-12-18
US20150367612A1 (en) 2015-12-24
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US10052850B2 (en) 2018-08-21
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US9139242B2 (en) 2015-09-22
KR20100017432A (ko) 2010-02-16

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