WO2016029775A1

WO2016029775A1 - Encapsulation structure and method for forming the same, and vehicle window

Info

Publication number: WO2016029775A1
Application number: PCT/CN2015/085536
Authority: WO
Inventors: Ce Shi; Yang Sun; Xiaohui Guo
Original assignee: Saint-Gobain Glass France
Priority date: 2014-08-25
Filing date: 2015-07-30
Publication date: 2016-03-03
Also published as: CN105437459A

Abstract

A method for forming an encapsulation structure, an encapsulation structure and a vehicle window are provided. The method includes: providing an insert component with an anti-rust layer formed thereon; applying a plasma treatment to the insert component to increase a surface tension of the anti-rust layer; coating the anti-rust layer of the insert component with primer; and injecting an encapsulation material to form the encapsulation structure. The encapsulation structure includes components formed by the aforementioned method. The vehicle window includes a glass substrate and the encapsulation structure formed by the aforementioned method. The encapsulation component can be well adhered with the insert component, such that it is not likely to drop off from the insert component. Therefore, yield of the encapsulation structures can be improved.

Description

ENCAPSULATION STRUCTURE AND METHOD FOR FORMING THE SAME, AND VEHICLE WINDOW

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to Chinese patent application No. 201410422096.0, filed on August 25, 2014, and entitled “ENCAPSULATION STRUCTURE AND METHOD FOR FORMING THE SAME, AND VEHICLE WINDOW” , and the entire disclosure of which is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure generally relates to vehicle technology, and more particularly, to a method for forming an encapsulation structure, an encapsulation structure and a vehicle window.

BACKGROUND

Between a vehicle bodywork and a vehicle window, there is normally provided an encapsulation structure to provide a better sealing effect, such that the vehicle window may have improved encapsulation features and thus can be mounted on the bodywork in an optimized way.

In existing techniques, an encapsulation structure may have an insert component inside of itself. The insert component can support the encapsulation structure, plus with some decorative function. Therefore, the existing encapsulation structure normally includes such an insert component and an encapsulation component encompassing the insert component.

Further, conventionally the encapsulation component is formed as an integrate structure on the outer surface of the insert component through an injection molding process, so that the encapsulation structure is formed. However, the encapsulation component is very likely to peel off from the insert component.

The encapsulation component peeling off from the insert component not only affects the aesthetics of the encapsulation structure, but also leads to a product failure and affects the yield. Besides, when such an encapsulation structure is matched with a glass substrate to form a vehicle window, the encapsulation component peeling off from the insert component can even result in the glass substrate falling off from the vehicle bodywork, which is a great harm for vehicle safety.

SUMMARY

In light of the above, there is a need for a method for forming an encapsulation structure, an encapsulation structure and a vehicle window, which can prevent an insert component from peeling off from an encapsulation component.

In one aspect, a method for forming an encapsulation structure is provided. The method includes: providing an insert component with an anti-rust layer formed thereon； applying a plasma treatment process to the insert component with the anti-rust layer to increase a surface tension of the anti-rust layer； after applying the plasma treatment process, coating the anti-rust layer of the insert component with a primer； and injecting an encapsulation material onto the insert component coated with the primer to form the encapsulation structure.

A basic idea is that, by applying the plasma treatment process to the insert component coated with the anti-rust layer, the anti-rust layer treated with plasma is activated. Or else, some contamination and impurity particles formerly existing on the surface of the anti-rust layer are removed by the plasma. As such, the surface tension of the anti-rust layer may be increased. Therefore, the primer can be ideally attached to the anti-rust layer of the insert component after it is coated onto the anti-rust layer. When the encapsulation component is formed on the insert component, it can be ideally adhered with the insert component through the primer. That is to say, the encapsulation structure may have an increased yield, as the encapsulation component thereof is not likely to peel off from the insert component.

According to another aspect, an encapsulation structure is provided. The encapsulation structure includes an insert component and an encapsulation component formed on a surface of the insert component by injection molding, wherein an anti-rust layer is formed on the surface of the insert component, and the anti-rust layer has an activated surface which has been subject to a plasma treatment process； wherein the activated surface of the anti-rust layer is coated with primer； and wherein the encapsulation component is adhered to the anti-rust layer of the insert component through the primer.

A basic idea is that, as the insert component has an anti-rust layer which is activated by a plasma treatment process, the activated surface of the anti-rust layer has a greater surface tension compared with a conventional anti-rust layer. The primer can be ideally attached to the activated surface of the anti-rust layer, thereby the encapsulation component can be adhered to the insert component through the primer in an optimized way. As such, in the encapsulation structure, the encapsulation component is not likely to peel off from the insert component.

According to another aspect, a vehicle window is provided, which includes an encapsulation structure formed by the aforesaid method, and further includes a glass substrate.

In the encapsulation structure, the encapsulation component is not likely to peel off from the insert component, therefore the glass substrate in the formed vehicle window is not likely to fall off from the bodywork of the vehicle. Both the safety and aesthetics of the vehicle can be improved.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGs. 1 to 2 schematically illustrate diagrams of a conventional insert component；

FIGs. 3 to 5 schematically illustrate diagrams of intermediate structures formed in a method for forming an encapsulation structure according to one embodiment； and

FIGs. 6 to 7 schematically illustrate diagrams of a vehicle window according to one embodiment.

DETAILED DESCRIPTION

Referring to FIGs. 1 and 2, structures of a conventional insert component and a conventional encapsulation component are illustrated. Normally, a layer of a primer is required to be disposed between the insert component and the encapsulation component for enhancing the adhesion. However, referring to FIG. 1, in existing techniques, an insert component 1 needs a surface treatment to form an anti-rust layer 2 for protection. The anti-rust layer 2 may have a relatively low surface tension. As a result, it may be difficult for a primer 4 (referring to FIG. 2) to be attached onto the surface of the insert component 1 coated with the anti-rust layer 2. In some occasions, the primer 4 may shrink and thus form multiple liquid drops. Specifically, although the anti-rust layer 2 may appear to be flat on a macro level, on a micro level it may have multiple tiny convex and concave portions. In practice, these convex and concave portions are very likely to be attached with some impurity or contamination particles which may lead to a reduction of the contact region between the subsequently formed the primer 4 and the anti-rust layer 2. As such, the surface tension of the anti-rust layer 2 relative to the primer 4 may decrease, and the primer 4 coated on the anti-rust layer 2 tends to shrink to form the liquid drops.

On the one hand, due to the impurity or contamination particles, the anti-rust layer 2 of the insert component 1 may not be able to ideally attach with the liquid-drop-shaped primer 4. On the other hand, as the primer 4 shrinks to form liquid drops, some portions of the anti-rust layer 2 of the insert component 1 are not covered by the primer 4 and thus become directly in contact with an encapsulation component formed by injection molding. Therefore, the adhesion between the anti-rust layer 2 and the encapsulation component doesn’ t reach a high quality standard. Due to the poor adhesion between the insert component 1 and the encapsulation component, the encapsulation component is very likely to peel off from the insert component 1. As a result, both the aesthetics of the entire encapsulation structure and the production yield will be affected. Furthermore, a potential safety risk also exists in a vehicle window formed with such an encapsulation structure.

Therefore, in order to solve the technical problems mentioned in the background, embodiments of the present disclosure provide a method for forming an encapsulation structure. FIGs. 3 to 5 schematically illustrate diagrams of intermediate structures formed in a method for forming an encapsulation structure according to one embodiment.

First, referring to FIG. 3, an insert component 100 is provided. In some embodiments, the insert component (or shortly called as “insert” ) may be a bright trim. After the encapsulation structure is formed, the bright trim may be partially covered by an encapsulation component in the encapsulation structure. The uncovered part of the bright trim can function as a decoration component. It should be noted that the insert component may have other configurations. In some embodiments, the insert component may be completely or mostly covered by the encapsulation component. In such configurations, the main function of the insert component is to support the encapsulation structure.

The insert component 100 is coated with an anti-rust layer 110.

In some embodiments, the insert component 100 may include iron, iron alloy, aluminum, aluminum alloy or high polymer material. However, the material of the insert component 100 is not limited to the aforesaid examples. In the present disclosure, a plasma treatment process is to be applied subsequently to the anti-rust layer 110 on the surface of the insert component 100.

In some embodiment, the anti-rust layer 110 may include epoxy resin. Epoxy resin is commonly used as an anti-rust material. However, the material of the anti-rust layer 110 is not limited to epoxy resin.

Thereafter, a plasma treatment process is applied to the insert component 100 coated with the anti-rust layer 110. The plasma treatment process is applied to increase the surface tension of the anti-rust layer 110.

Specifically, the plasma treatment process aims to remove the contaminations, impurity particles, etc., attached on the surface of the anti-rust layer 110, thereby increasing the surface tension of the anti-rust layer 110. Furthermore, the plasma treatment process aims to activate the surface of the anti-rust layer 110, and thus further increase the surface tension of the anti-rust layer 110. Therefore, in a subsequent coating process, the primer is more likely to be coated onto the surface of the anti-rust layer 110.

In some embodiments, the increased surface tension of the anti-rust layer 110 may at least reach 72mN/m, such that the primer can be ideally coated to the surface of the anti-rust layer 110 in following processing.

It should be noted that the above described parameter, 72mN/m, is merely an example. The required magnitude of the surface tension of the anti-rust layer 110 varies based on practical conditions, for example the components of the primer. The present disclosure is not limited to the above embodiments. Besides, by adjusting the parameters of the plasma treatment process, the resulting surface tension of the anti-rust layer 110 can be controlled to reach different levels.

In some embodiments, the plasma treatment process is an atmospheric pressure plasma treatment process, i.e., it is implemented at ambient atmospheric pressure. Such a plasma treatment process can enhance the surface tension of the anti-rust layer 110, as described above, and also save the cost. However, the plasma treatment process is not limited to an atmospheric pressure plasma treatment process. In some embodiments, the plasma treatment process may be selected from other plasma treatment processes, for example, it may be a vacuum plasma treatment process implemented at a pressure below 100pa.

In some embodiments, the plasma treatment process can directly use air as its gas source. In such a configuration, the process can be simply applied as no extra gas source is dedicatedly required. However, the present disclosure is not limited to the embodiments. In some other embodiments, inert gases, nitrogen, etc., can also be selected as the gas source of the plasma treatment process.

Specifically, a plasma treatment device including a nozzle 200 may be used in the plasma treatment process applied to the anti-rust layer 110. Plasma flow 201 may be sprayed from the nozzle 200 and hit the surface of the anti-rust layer 110. As such, the contaminants and impurity particles on the surface of the anti-rust layer 110 can be removed, and the surface of the anti-rust layer 110 can be activated.

It should be noted that over treating the surface of the anti-rust layer 110 may bring several drawbacks. For example, the anti-rust layer 110 may be thinned too much to provide its original function, i.e., rust-proof. Besides, a too long treating period may increase the manufacturing cost, which is not necessary. Therefore, in order to increase the surface tension of the anti-rust layer 110 to more than 72mN/m and meanwhile avoid over treating the surface of the anti-rust layer 110, parameters of the plasma treatment process may be configured as follows: the plasma treatment device has an output power ranging from 300W to 1500W, a distance between the nozzle 200 and the anti-rust layer 110 is set from 3mm to 25mm, and the nozzle 200 moves relative to the insert component 100 (i.e., relative to the anti-rust layer 110) at a speed ranging from 3m/minute to 60m/minute.

For example, in a specific embodiment, air is used as the gas source of the plasma treatment process, the output power of the plasma treatment device is set as 300W, the distance between the nozzle 200 and the anti-rust layer 110 is set as 25mm, and the nozzle 200 moves relative to the anti-rust layer 110 at a speed of 60m/minute. In such an embodiment, the output power of the plasma treatment device is relatively low, the distance between the nozzle 200 and the surface of the anti-rust layer 110 is relatively long, and the moving speed of the nozzle 200 relative to the anti-rust layer 110 is relatively fast, which means the processing intensity of the plasma treatment process applied to the anti-rust layer 110 is relatively low. In such a configuration, the surface tension of the anti-rust layer 110 can be increased to the required level, while the anti-rust layer 110 will not be overly treated. The thickness of the anti-rust layer 110 can be maintained enough to provide its anti-rust function. According to practical experiments, after the aforesaid plasma treatment process, the surface tension of the anti-rust layer 110 is increased to beyond 72mN/m.

Referring to FIG. 4, after the plasma treatment process is applied to the anti-rust layer 110, a primer 120 is coated on the anti-rust layer 110 of the insert component 100. The primer 120 is used for enhancing the adhesion between the insert component 100 formed with the anti-rust layer 110 and the subsequently formed encapsulation component.

As described above, the anti-rust layer 110, which has been subject to the plasma treatment process, has in increased surface tension. Therefore, compared with existing techniques, the primer 120 can be more easily attached to the surface of the anti-rust layer 110. In conventional practices, the primer may shrink to form liquid drops on the anti-rust layer. However, in embodiments of the present disclosure, the primer 120 may be more evenly distributed on the anti-rust layer 110, thereby forming a thin film attached thereon.

In some embodiments, the primer 120 may include polyurethane. Polyurethane can be used as the effective ingredient in the primer 120, attribute to its strong adhesion with both the anti-rust layer 110 made of epoxy resin and the encapsulation component formed in following processing.

In some embodiments, the primer 120 may be solvent-based. Specifically, the solution of the solvent-based primer may include methylbenzene, dimethylbenzene, ethyl acetate, methyl cyclohexane or propylene glycol monomethyl ether acetate. However, the solution is not limited to the above examples, and it can be adjusted based on practical needs.

It should be noted that the primer is not limited to a solvent-based primer. In some embodiments, the primer 120 may be water-based, that is to say, the solution of the primer 120 is water.

It should be noted that the effective ingredient and solution of the primer may be adjusted based on the materials of the anti-rust layer 110 and/or the encapsulation component, so as to achieve an ideal adhesion among the anti-rust layer 110, the primer 120 and the encapsulation component.

Referring to FIG. 5, after the primer 120 is coated on the insert component 100, the insert component 100 coated with the primer 120 is subject to an injection molding process to form an encapsulation component 120 thereon. Thus, the encapsulation structure is formed. As the adhesion between the primer 120 and the encapsulation component 130 is relatively strong, and the adhesion between the primer 120 and the anti-rust layer 110 is also strong, the encapsulation component 130 is not likely to peel off from the insert component 100, thereby improving the production yield of the encapsulation structure.

In some embodiments, the encapsulation component 130 may be formed with PVC material. However, the present disclosure is not limited to these embodiments.

In another specific embodiment, the plasma treatment process may be configured as follows. The output power of the plasma treatment device is set as 1500W, the distance between the nozzle 200 and the anti-rust layer 110 is set as 3mm, and the nozzle 200 moves relative to the anti-rust layer 110 at a speed of 3m/minute. In such an embodiment, the output power of the plasma treatment device is relatively high, the distance between the nozzle 200 and the surface of the anti-rust layer 110 is relatively short, and the moving speed of the nozzle 200 relative to the anti-rust layer 110 is relatively slow, which means the processing intensity of the plasma treatment process applied to the anti-rust layer 110 is relatively strong. In such a configuration, the surface tension of the anti-rust layer 110 can be increased as much as possible.

In another specific embodiment, the plasma treatment process may be configured as follows. The output power of the plasma treatment device is set as 400W, the distance between the nozzle 200 and the anti-rust layer 110 is set as 6mm, and the nozzle 200 moves relative to the anti-rust layer 110 at a speed of 10m/minute. In such an embodiment, the output power of the plasma treatment device is relatively low, the distance between the nozzle 200 and the surface of the anti-rust layer 110 is relatively short, and the moving speed of the nozzle 200 relative to the anti-rust layer 110 is relatively slow. In such a configuration, although the output power is reduced, which is benefit for saving cost, the nozzle 200 is set to be closer to the anti-rust layer 110 and the speed is set to be slow. Therefore, the processing intensity of the plasma treatment process applied to the anti-rust layer 110 is still maintained at a high level, and thus the surface tension of the anti-rust layer 110 can still be increased to the required value.

In another specific embodiment, the plasma treatment process may be configured as follows. The output power of the plasma treatment device is set as 900W, the distance between the nozzle 200 and the anti-rust layer 110 is set as 14mm, and the nozzle 200 moves relative to the anti-rust layer 110 at a speed of 61.5m/minute. In such an embodiment, the output power of the plasma treatment device, the distance between the nozzle 200 and the surface of the anti-rust layer 110, and the moving speed of the nozzle 200 relative to the anti-rust layer 110 are all set at an intermediate level. Therefore, the surface tension of the anti-rust layer 110 can still be increased to the required level.

In light of the above, it could be concluded that parameters of the plasma treatment process (the output power of the plasma treatment device, the distance between the nozzle and the anti-rust layer, and the moving speed of the nozzle relative to the anti-rust layer) may vary based on practical conditions and requirements. Therefore, the present disclosure is not limited to the above embodiments illustrating the specific process parameters.

According to another embodiment of the present disclosure, an encapsulation structure is provided, the structure of which is illustrated in FIG. 5.

Referring to FIG. 5, the encapsulation structure includes: an insert component 100 and an encapsulation component 130 formed on a surface of the insert component 100 by an injection molding process. In some embodiments, the insert component 100 may include iron, iron alloy, aluminum, aluminum alloy or high polymer material. However, the material of the insert component 100 is not limited to the aforesaid examples. In the present disclosure, a plasma treatment process is to be applied subsequently to the anti-rust layer 110 on the surface of the insert component 100.

The insert component 100 is formed with an anti-rust layer 110 on the surface thereof.

In some embodiments, the anti-rust layer 11 is an epoxy resin anti-rust layer.

A surface of the anti-rust layer 11 is an activated surface treated by plasma.

In some embodiments, the surface of the anti-rust layer 11 is an activated surface treated by an atmospheric pressure plasma treatment process. However, the plasma treatment process is not limited to the specific type mentioned above. As long as the plasma treatment process can activate the surface of the anti-rust layer 110, it may be selected in the present disclosure. In some embodiments, the surface of the anti-rust layer 11 is an activated surface treated by a vacuum plasma treatment process.

The activated surface of the anti-rust layer 110 is coated with a primer 120.

In some embodiments, the primer 120 includes polyurethane.

The encapsulation component 130 is adhered to the anti-rust layer 110 formed on the insert component 100 through the primer 120, thereby constituting the encapsulation structure.

Specifically, the encapsulation component 130 may be formed as an integrate structure on the anti-rust layer 110 on the surface of the insert component 100 by an injection molding process.

It should be noted that the encapsulation structure provided in the present disclosure may be formed, but not limited to, by the method described above.

Further, a vehicle window is provided according to one embodiment. FIG. 6 schematically illustrates a plane view of the vehicle window, and FIG. 7 schematically illustrates a cross section of a part of the vehicle window.

The vehicle window includes a glass substrate 60 and an encapsulation structure 10 (referring to FIG. 6) formed by the aforesaid method for forming an encapsulation structure.

The encapsulation structure 10 includes an insert component 101, an anti-rust layer 111, a primer 121 and an encapsulation component 131 (referring to FIG. 7) . The encapsulation component 131 is formed to cover an edge portion of the glass substrate 60 by an injection molding process, such that the encapsulation structure 10 can be fixed with the glass substrate 60.

When the vehicle window is in use, it may be mounted on a vehicle bodywork 50. Specifically, in some embodiments, the vehicle window is mounted in such a way that the insert component 101 is disposed towards the vehicle bodywork 50. As such, the encapsulation structure 10, together with the glass substrate 60, is mounted on the vehicle bodywork 50.

As the encapsulation component 131 in the encapsulation structure 10 is not likely to peel off from the insert component 101, the glass substrate 60 in the vehicle window formed in such a way is less likely to fall off from the vehicle bodywork 50. Therefore, both the aesthetics and safety of the vehicle can be improved.

Although the present disclosure has been disclosed above with reference to preferred embodiments thereof, it should be understood that the disclosure is presented by way of example only, and not limitation. Those skilled in the art can modify and vary the embodiments without departing from the spirit and scope of the present disclosure. Therefore, the protection scope of the present disclosure is subject to the scope defined by the claims.

Claims

A method for forming an encapsulation structure, comprising:

providing an insert component with an anti-rust layer formed thereon；

applying a plasma treatment process to the insert component with the anti-rust layer to increase a surface tension of the anti-rust layer；

after applying the plasma treatment process, coating the anti-rust layer of the insert component with a primer； and

injecting an encapsulation material onto the insert component coated with the primer to form the encapsulation structure.
The method according to claim 1, wherein the insert component comprises iron, iron alloy, aluminum, aluminum alloy or high polymer material.
The method according to claim 1, wherein the anti-rust layer comprises epoxy resin.
The method according to claim 1, wherein the primer comprises polyurethane.
The method according to claim 1, wherein the primer is water-based or solvent-based.
The method according to claim 5, wherein the solvent-based primer comprises methylbenzene, dimethylbenzene, ethyl acetate, methyl cyclohexane or propylene glycol monomethyl ether acetate.
The method according to claim 1, wherein the plasma treatment process is an atmospheric pressure plasma treatment process or a vacuum plasma treatment process.
The method according to claim 1, wherein the plasma treatment process uses air as a gas source.
The method according to claim 1, wherein the plasma treatment process comprises: using a plasma treatment device comprising a nozzle to apply the plasma treatment process to the insert component with the anti-rust layer, wherein the plasma treatment device has an output power ranging from 300W to 1500W, a distance between the nozzle and the anti-rust layer is set from 3mm to 25mm, and the nozzle moves relative to the insert component at a speed ranging from 3m/minute to 60m/minute.
An encapsulation structure, comprising an insert component and an encapsulation component formed on a surface of the insert component by injection molding, wherein an anti-rust layer is formed on the surface of the insert component, and the anti-rust layer has an activated surface which has been subject to a plasma treatment process；

wherein the activated surface of the anti-rust layer is coated with a primer； and

wherein the encapsulation component is adhered to the anti-rust layer of the insert component through the primer.
The encapsulation structure according to claim 10, wherein the activated surface has been subject to an atmospheric pressure plasma treatment process or a vacuum plasma treatment process.
The encapsulation structure according to claim 10, wherein the anti-rust layer is an epoxy resin anti-rust layer.
The encapsulation structure according to claim 10, wherein the insert component comprises iron, iron alloy, aluminum, aluminum alloy or high polymer material.
The encapsulation structure according to claim 10, wherein the primer comprises polyurethane.
A vehicle window, comprising:

a glass substrate； and

an encapsulation structure formed by the method according to any one of claims 1 to 9.