WO2021105879A1

WO2021105879A1 - System and method for laminating an optical film to a windshield

Info

Publication number: WO2021105879A1
Application number: PCT/IB2020/061093
Authority: WO
Inventors: Ryan J. EISMIN; Eileen M. FRANEY; Matthew B. Johnson
Original assignee: 3M Innovative Properties Company
Priority date: 2019-11-25
Filing date: 2020-11-24
Publication date: 2021-06-03
Also published as: JP2023502767A; CN212194618U

Abstract

A system for laminating an optical film to a windshield is provided. The optical film includes an optically clear adhesive disposed on a bottom surface thereof. The system includes a clamping arrangement including a plurality of clamps for holding the optical film along an outer periphery thereof. Each of the plurality of clamps is adapted to apply a tension on the optical film. The system also includes a fixture including a support structure for supporting the windshield thereon. A shape of an upper surface of the support structure is similar to a shape of the windshield. The system further includes a pressing mechanism adapted to provide contact between the optical film and the windshield such that the optical film conforms to the shape of the windshield based on the tension applied on the optical film. Further, the optically clear adhesive is adapted to bond the optical film with the windshield.

Description

SYSTEM AND METHOD FOR LAMINATING AN OPTICAL FILM TO A

WINDSHIELD

Technical Field

The present disclosure relates to lamination of optical films to windshields, and more particularly to systems and methods for laminating an optical film to a windshield.

Background

A windshield of an automobile is typically laminated with an optical film, such as a multilayer optical film or a window combiner film, so that virtual reality heads-up displays may be incorporated on the windshield. The optical film acts as a single reflection surface that allows elimination of ghosting and enables wider viewing angles. A process of laminating the optical film to the windshield poses challenges due a three- dimensional curvature of the windshield. Further, processes that are currently being used for laminating the optical film to the windshield may cause buckling of the optical film during lamination, which is not desirable. It may therefore be desirable to have an improved system and method that allows easier and secure lamination of the optical film to the windshield.

Summary

Generally, the present disclosure relates to systems and method used for lamination of optical film to windshields.

Some embodiments of the present disclosure relate to a system for laminating an optical film to a windshield. The optical film includes an optically clear adhesive disposed on a bottom surface thereof. The system includes a clamping arrangement including a plurality of clamps for holding the optical film along an outer periphery thereof. Each of the plurality of clamps is adapted to apply a tension on the optical film. The system also includes a fixture including a support structure for supporting the windshield thereon. A shape of an upper surface of the support structure is similar to a shape of the windshield. The system further includes a pressing mechanism adapted to provide contact between the optical film and the windshield such that the optical film conforms to the shape of the windshield based on the tension applied on the optical film. Further, the optically clear adhesive is adapted to bond the optical film with the windshield.

In some embodiments, the pressing mechanism is further adapted to move the clamping arrangement towards the support structure in order to press the optical film against the windshield.

In some embodiments, the pressing mechanism is further adapted to press the optical film against the windshield with a pressure from about 10 kPa to about 1000 kPa.

In some embodiments, the pressing mechanism is further adapted to move the support structure towards the clamping arrangement in order to press the windshield against the optical film.

In some embodiments, the pressing mechanism is further adapted to press the windshield against the optical film with a pressure from about 10 kPa to about 1000 kPa.

In some embodiments, the clamping arrangement is further adapted to apply a maximum tension of about 100 MPa on the optical film.

In some embodiments, the system further includes a heating module for increasing a temperature of the optical film.

In some embodiments, the clamping arrangement is further adapted to increase the tension applied on the optical film by each of the plurality of clamps upon contact of the optical film with the windshield.

In some embodiments, the pressing mechanism includes at least one of a hydraulic press and a mechanical press.

In some embodiments, the system further includes a roller mechanism adapted to apply a pressure on the optical film for laminating the optical film to the windshield.

In some embodiments, the roller mechanism further includes at least one roller, the at least one roller contacting the optical film with a pressure from about 10 kPa to about 1000 kPa.

In some embodiments, the pressing mechanism is further adapted to establish a first point of contact between the optical film and the windshield based on a contact of a central portion of the optical film with a central portion of the windshield. In some embodiments, the pressing mechanism is further adapted to establish a first point of contact between the optical film and the windshield based on a contact of an edge of the optical film with an edge of the windshield.

In some embodiments, the optical film is laminated to the windshield in a vacuum environment.

Some embodiments of the present disclosure relate to a method of laminating an optical film to a windshield. The optical film includes an optically clear adhesive disposed on a bottom surface thereof. The method includes holding the optical film along an outer periphery thereof using a clamping arrangement including a plurality of clamps. Each of the plurality of clamps is adapted to apply a tension on the optical film. The method also includes supporting the windshield on a fixture including a support structure. A shape of an upper surface of the support structure is similar to a shape of the windshield. The method further includes moving at least one of the clamping arrangement and the support structure using a pressing mechanism to provide contact between the optical film and the windshield such that the optical film conforms to the shape of the windshield based on the tension applied on the optical film. The optically clear adhesive is adapted to bond the optical film with the windshield.

Some embodiments of the present disclosure relate to a system for laminating an optical film to a windshield. The optical film includes an optically clear adhesive disposed on a bottom surface thereof. The system includes a clamping arrangement including a plurality of clamps for holding the optical film along an outer periphery thereof. Each of the plurality of clamps is adapted to apply a tension on the optical film. The system also includes a fixture including a support structure for supporting the windshield thereon. A shape of an upper surface of the support structure is similar to a shape of the windshield. The system further includes a pressing mechanism adapted to provide contact between the optical film and the windshield such that the optical film conforms to the shape of the windshield based on the tension applied on the optical film. The optically clear adhesive is adapted to bond the optical film with the windshield. Further, the pressing mechanism is adapted to provide contact between the optical film and the windshield based on a movement of at least one of the clamping arrangement and the support structure. Brief Description of the Drawings

Exemplary embodiments disclosed herein may be more completely understood in consideration of the following detailed description in connection with the following figures. The figures are not necessarily drawn to scale. Like numerals used in the figures refer to like components. When pluralities of similar elements are present, a single reference numeral may be assigned to each plurality of similar elements with a small letter designation referring to specific elements. When referring to the elements collectively or to a non-specific one or more of the elements, the small letter designation may be eliminated. However, it will be understood that the use of a numeral to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.

FIG. l is a perspective view of a windshield and an optical film laminated to the windshield according to an embodiment of the present disclosure;

FIG. 2 is a perspective view of a system for laminating the optical film to the windshield shown in FIG. 1 according to an embodiment of the present disclosure;

FIG. 3 is a perspective view of an exemplary set-up illustrating a clamping arrangement for applying tension on the optical film shown in FIG. 1 and a heating module for increasing a temperature of the optical film according to an embodiment of the present disclosure;

FIG. 4 is a schematic view illustrating the optical film held by clamps of the clamping arrangement shown in FIG. 3;

FIG. 5 is a schematic view illustrating a pressing mechanism for moving the clamping arrangement shown in FIGS. 3 and 4 for lamination of the optical film to the windshield according to an embodiment of the present disclosure;

FIG. 6 is a schematic view of an exemplary set-up illustrating a pressing mechanism for moving a support structure for lamination of the optical film to the windshield shown in FIG. 1 according to an embodiment of the present disclosure;

FIGS. 7 and 8 are schematic views of an exemplary set-up illustrating a roller mechanism for lamination of the optical film to the windshield shown in FIG. 1 according to an embodiment of the present disclosure; and

FIG. 9 is a flowchart for a method of laminating the optical film to the windshield according to an embodiment of the present disclosure. Detailed Description

In the following description, reference is made to the accompanying figures that form a part thereof and in which various embodiments are shown by way of illustration. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present disclosure. The following detailed description, therefore, is not to be taken in a limiting sense.

The present disclosure relates to a method and systems for laminating optical films to windshields. The method and systems may be used to laminate windshields of automobiles for enabling virtual reality heads-up displays on such windshields. The method and systems may be used for laminating multi-layer optical films or window combiner films coated with an optically clear pressure sensitive adhesive to a three- dimensional full-sized windshield. The system includes a clamping arrangement for holding the optical film under tension such that the optical film stretches and conforms to a shape of the windshield without inducing buckles in the optical film during the lamination process. In some examples, the optical film may be heated in order to soften the optical film which may in turn allow the optical film to easily conform to the windshield.

FIG. 1 illustrates an exemplary windshield 100 and an optical film 102 that is laminated to the windshield 100. The windshield 100 may be embodied as a three- dimensional full-sized windshield that may be used in automobiles. The windshield 100 defines a curvature. In an example, the windshield 100 may be made from glass. Further, the windshield 100 defines a first surface 104 (shown in FIG. 3) and a second surface 106 that is disposed opposite to the first surface 104. The windshield 100 defines a first edge 128 and a second edge 130 disposed opposite to the first edge 128. It should be noted that a size and a shape of the windshield 100 illustrated herein is exemplary in nature, and the size and the shape of the windshield 100 may vary as per application requirements.

Further, the optical film 102 may embody an optical film generally known in the art that allows incorporation of virtual reality heads-up display, eliminates ghosting, and enables wider viewing angles. In an example, the optical film 102 may include a multi layer optical film that provides a single reflection surface. In another example, the optical film 102 may include a window combiner film. In some examples, the size of the optical film 102 may be greater than the size of the windshield 100. In such examples, the optical film 102 may be subjected to a finishing process so that dimensions of the optical film 102 conform with dimensions of the windshield 100.

Further, the optical film 102 defines an outer periphery 108, an upper surface 110, and a bottom surface 112 that is disposed opposite to the upper surface 110. The optical film 102 also defines a first edge 114, a second edge 116 parallel to the first edge 114, a third edge 118 extending between the first and second edges 114, 116, and a fourth edge 120 that is parallel to the third edge 118. The optical film 102 includes an optically clear adhesive 122 (shown in FIG. 4) disposed on the bottom surface 112 thereof. The optically clear adhesive 122 is adapted to bond the optical film 102 with the windshield 100. More particularly, the optically clear adhesive 122 bonds the first surface 104 of the windshield 100 with the bottom surface 112 of the optical film 102. In an example, the optically clear adhesive 122 may be embodied as a pressure sensitive optically clear adhesive.

Referring to FIG. 2, the present disclosure relates to a system 200 for laminating the optical film 102 to the windshield 100. The system 200 includes a clamping arrangement 202, a fixture 228, a support structure 230, and a pressing mechanism 224. In the illustrated embodiment, the pressing mechanism 224 is associated with the clamping arrangement 202 to initiate a movement of the clamping arrangement 202 in order to allow contact between the optical film 102 and the windshield 100 during the lamination process. Alternatively, the pressing mechanism 224 may move the support structure 230 in order to allow contact between the optical film 102 and the windshield 100 during the lamination process.

As illustrated in FIG. 3, the system 200 includes the clamping arrangement 202. The clamping arrangement 202 includes a plurality of clamps 204, 206, 208, 210 for holding the optical film 102 along the outer periphery 108 (shown in FIG. 1) thereof.

Each of the plurality of clamps 204, 206, 208, 210 is adapted to apply a tension on the optical film 102. It should be noted that the clamping arrangement 202 may itself include a mechanism for applying tension on the optical film 102. For example, the mechanism for applying tension may include one or more components that allow movement of the clamps 204, 206, 208, 210 in an outward direction to stretch the optical film 102. Further, the clamping arrangement 202 is adapted to increase the tension applied on the optical film 102 by each of the plurality of clamps 204, 206, 208, 210 upon contact of the optical film 102 with the windshield 100. More particularly, the tension applied on the optical film 102 by the clamping arrangement 202 is minimum before the optical film 102 and the windshield 100 contact each other. Further, the tension is increased gradually as the optical film 102 and the windshield 100 are pressed against each other. In some examples, the clamping arrangement 202 is adapted to apply a maximum tension of about 100 MPa (Megapascal) on the optical film 102. The clamping arrangement 202 also includes a frame 212 that is generally rectangular in shape. The optical film 102 is held by the clamps 204, 206, 208, 210 and the frame 212.

In an example, the clamping arrangement 202 includes ten clamps 204, 206, 208, 210. However, a total number of the clamps 204, 206, 208, 210 may vary as per the dimensions of the optical film 102. In the illustrated example, the clamping arrangement 202 includes two clamps 204 disposed at the first edge 114 of the optical film 102 and two clamps 206 disposed at the second edge 116 of the optical film 102. Further, the clamping arrangement 202 includes three clamps 208 disposed at the third edge 118 of the optical film 102 and three clamps 210 disposed at the fourth edge 120 of the optical film 102. As shown in FIG. 4, the clamping arrangement 202 is adapted to maintain equal distances “Bl” between the clamps 204 and the clamps 206 along a first axis “Al”. Further, the equal distances “Bl” between the clamps 204 and the clamps 206 are also maintained during the application of the tension on the optical film 102. Further, the clamping arrangement 202 is adapted to maintain equal distances “B2” between the clamps 208 and the clamps 210 along a second axis “A2”. Further, the equal distances “B2” between the clamps 208 and the clamps 210 are also maintained during the application of the tension on the optical film 102. The clamps 204, 206, 208, 210 may apply the tension along a plane of the optical film 102, i.e., along the first and second axes “Al”, “A2”.

The clamps 204, 206, 208, 210 may be embodied as adjustable clamps that are generally known in the art for accommodating optical films of varying thicknesses. Further, each of the clamps 204, 206, 208, 210 includes a bar 216, 218, 220, 222 (shown in FIG. 3), respectively, that allows attachment of the corresponding clamp 204, 206, 208, 210 to the pressing mechanism 224 (see FIG. 2) and/or the mechanism (not shown) that is associated with the clamping arrangement 202 for applying the tension on the optical film 102. The clamps 204, 206, 208, 210 and the bars 216, 218, 220, 222 together allow suspension and alignment of the optical film 102 with respect to the windshield 100 (see FIGS. 1 and 2).

Referring now to FIG. 5, in the illustrated embodiment, the clamping arrangement 202 is movable in order to press the optical film 102 against the windshield 100 during the lamination process. The clamping arrangement 202 is movable along a third axis “A3” that is generally embodied as a vertical axis. More particularly, the pressing mechanism 224 is adapted to initiate a movement of the clamping arrangement 202 and the optical film 102 that is held by the clamps 204, 206, 208, 210 (see FIGS. 3 and 4). In another embodiment, the clamping arrangement 202 may be held stationary (as shown in FIG. 6). In such an embodiment, the clamps 204, 206, 208, 210 may be fixedly attached to a frame of the system 200 via the corresponding bars 216, 218, 220, 222 (see FIG. 3).

Further, the system 200 also includes a heating module 226. The heating module 226 increases a temperature of the optical film 102. More particularly, the heating module 226 is used to apply heat to the optical film 102 when the optical film 102 is being subjected to tension. In an example, a temperature to which the optical film 102 is subjected during the lamination process may lie between room temperature and 200° Centigrade. The application of heat softens the optical film 102 and allows the optical film 102 to conform with the windshield 100 easily. The heating module 226 may include any conductive, radiative, and/or convective source of heat that may be generally known in the art.

The system 200 includes the fixture 228. The fixture 228 includes the support structure 230 for supporting the windshield 100 thereon. A shape of an upper surface 232 of the support structure 230 is similar to the shape of the windshield 100. More particularly, the support structure 230 defines a curvature at the upper surface 232 that corresponds to the curvature of the windshield 100 to receive the windshield 100. In the illustrated embodiment, the fixture 228 and the support structure 230 are embodied as stationary components. The fixture 228 and the support structure 230 may be fixedly attached to a frame of the system 200. Alternatively, the fixture 228 and/or the support structure 230 may be movable by the pressing mechanism 224 in order to press the windshield 100 into the optical film 102 during the lamination process.

The system 200 also includes the pressing mechanism 224 adapted to provide contact between the optical film 102 and the windshield 100 such that the optical film 102 conforms to the shape of the windshield 100 based on the tension applied on the optical film 102. The pressing mechanism 224 is adapted to provide contact between the optical film 102 and the windshield 100 based on the movement of at least one of the clamping arrangement 202 and the support structure 230. The pressing mechanism 224 is adapted to establish a first point of contact between the optical film 102 and the windshield 100 based on a contact of a central portion 124 of the optical film 102 with a central portion 126 of the windshield 100. Alternatively, the pressing mechanism 224 may be adapted to establish the first point of contact between the optical film 102 and the windshield 100 based on a contact of one of the edges 114, 116 of the optical film 102 with the corresponding edges 128, 130 of the windshield 100.

In the illustrated embodiment, the pressing mechanism 224 is adapted to move the clamping arrangement 202 towards the support structure 230 in order to press the optical film 102 against the windshield 100. More particularly, the pressing mechanism 224 is adapted to move the bars 216, 218, 220, 222 to move the clamps 204, 206, 208, 210 and the optical film 102 along the third axis “A3” towards the windshield 100. In some examples, the pressing mechanism 224 is adapted to press the optical film 102 against the windshield 100 with a pressure from about 10 kPa (kilopascal) to about 1000 kPa. In one example, the pressure at which the pressing mechanism 224 is adapted to press the optical film 102 against the windshield 100 may lie between 200 kPa and 300 kPa. It should be noted that the pressing mechanism 224 may apply the pressure on the optical film 102 until the optical film 102 is fully laminated to the windshield 100. Thus, the pressing mechanism 224 may remain in an actuated state until the optical film 102 is fully laminated to the windshield 100. In some examples, a total time required for lamination of the windshield 100 may vary between 10 seconds and 60 seconds. The total time required for lamination may be defined as a time window from a first contact of the windshield 100 and the optical film 102 and a time instance at which the optical film 102 is fully laminated to the windshield 100. It should be noted that the pressing mechanism 224 may remain in the actuated state for a time period that is greater than the total time required for lamination of the windshield 100.

The pressing mechanism 224 includes at least one of a hydraulic press and a mechanical press. In an example wherein the pressing mechanism 224 is embodied as the hydraulic press, the system 200 may include one or more hydraulic components that allow movement of the clamping arrangement 202 or the support structure 230 during the lamination process. For example, the hydraulic press may include a piston cylinder arrangement. In another example wherein the pressing mechanism 224 is embodied as the mechanical press, one or more mechanical components may allow movement of the clamping arrangement 202 or the support structure 230 during the lamination process. In some examples, the mechanical press may include a motor that initiates the movement of the clamping arrangement 202 or the support structure 230. Further, the pressing mechanism 224 may embody a pneumatic press. Moreover, the pressing mechanism 224 may embody an automated system that is electronically controlled for movement of the clamping arrangement 202 or the support structure 230 during the lamination process.

Further, details, components, and arrangement of the clamping arrangement 202, the mechanism for applying the tension on the optical film 102, the heating module 226, the fixture 228, the support structure 230, and the pressing mechanism 224 described herein are purely exemplary in nature and the system 200 may include any other arrangement of components to fulfill the purpose of each of the clamping arrangement 202, the mechanism for applying the tension on the optical film 102, the heating module 226, the fixture 228, the support structure 230, and the pressing mechanism 224, without deviating from the scope of the present disclosure.

Further, in one example, the optical film 102 is laminated to the windshield 100 in a vacuum environment. In such an example, the system 200 may be enclosed in a vacuum chamber (not shown). Moreover, a pressure in the vacuum chamber may be dropped to a suitable level, such as 0.1 Pa, during the lamination process. Such a technique may reduce trapping of air between the optical film 102 and the windshield 100.

FIG. 6 illustrates a schematic view of another exemplary system 600. The system 600 is similar to the system 200 described earlier with reference to FIGS. 2 to 5. Accordingly, details and functions of a clamping arrangement 602, a mechanism for applying the tension on the optical film 102, a heating module 626, a fixture 628, a support structure 630, and a pressing mechanism 624 associated with the system 600 are similar to details and functions of the clamping arrangement 202, the mechanism for applying the tension on the optical film 102, the heating module 226, the fixture 228, the support structure 230, and the pressing mechanism 224, respectively, of the system 200. The Optical film 102 is held by clamps 604, 606 that are similar to the clamps 204, 206 described earlier with reference to FIGS. 3 to 5.

In this embodiment, the pressing mechanism 624 is adapted to establish the first point of contact between the optical film 102 and the windshield 100 based on the contact of the central portion 124 of the optical film 102 with the central portion 126 of the windshield 100. Further, the fixture 228 and/or the support structure 230 are movable along the third axis “A3”. More particularly, the pressing mechanism 624 is adapted to move the support structure 630 towards the clamping arrangement 602 in order to press the windshield 100 against the optical film 102. Thus, the pressing mechanism 624 is associated with the fixture 628 and the support structure 630 to move the support structure 630 along the third axis “A3” towards the clamping arrangement 602. In an example, the fixture 228 may itself actuate and move in order to move the support structure 230 along the third axis “A3”. Alternatively, the fixture 228 may include components (not shown), such as a piston cylinder arrangement, that allow the support structure 230 to move along the third axis “A3”. Further, in this embodiment, the clamping arrangement 602 remains in a stationary state.

In some examples, the pressing mechanism 624 is adapted to press the windshield 100 against the optical film 102 with a pressure from about 10 kPa to about 1000 kPa. In one example, the pressure at which the pressing mechanism 624 is adapted to press the windshield 100 into the optical film 102 may lie between 200 kPa and 300 kPa. It should be noted that the pressing mechanism 624 may continue the application of pressure on the support structure 630 to push the windshield 100 into the optical film 102 until the optical film 102 is fully laminated to the windshield 100.

Further, in one example, the optical film 102 is laminated to the windshield 100 in a vacuum environment. In such an example, the system 600 may be enclosed in a vacuum chamber (not shown). Moreover, a pressure in the vacuum chamber may be dropped to a suitable level, such as 0.1 Pa, during the lamination process. Such a technique may reduce trapping of air between the optical film 102 and the windshield 100.

FIGS. 7 and 8 illustrate schematic views of yet another exemplary system 700.

The system 700 is similar to the system 200 described earlier with reference to FIGS. 2 to 5. Accordingly, details and functions of a clamping arrangement 702, a mechanism for applying the tension on the optical film 102, a heating module 726, a fixture (not shown), a support structure 730, and a pressing mechanism (not shown) associated with the system 700 are similar to details and functions of the clamping arrangement 202, the mechanism for applying the tension on the optical film 102, the heating module 226, the fixture 228, and the pressing mechanism 224, respectively, of the system 200. Further, the optical film 102 is held by clamps 704, 706 that are similar to the clamps 204, 206 described earlier with reference to FIGS. 3 to 5.

In this embodiment, the pressing mechanism is adapted to establish a first point of contact between the optical film 102 and the windshield 100 based on the contact of the edge 114 of the optical film 102 with the edge 128 of the windshield 100. Further, in the illustrated embodiment, the pressing mechanism may be adapted to move either the clamping arrangement 702 or the support structure 730 until one of the edges 114, 116 of the optical film 102 contacts the corresponding edge 128, 130 of the windshield 100.

More particularly, the pressing mechanism of this embodiment does not press the optical film 102 and the windshield 100 against each other as illustrated in the embodiments described in reference to FIG. 2 and 5.

Further, the clamping arrangement 702 is adapted to apply the tension on the optical film 102 during the lamination process. Moreover, the system 700 includes a roller mechanism 732. The roller mechanism 732 is adapted to apply a pressure on the optical film 102 for laminating the optical film 102 to the windshield 100. The roller mechanism 732 includes at least one roller 734, the at least one roller 734 contacting the optical film 102 with a pressure from about 10 kPa to about 1000 kPa. In the illustrated embodiment, the roller 734 of the roller mechanism 732 travels along a length of the windshield 100 in a direction “Dl”, along the curvature of the windshield 100. It should be noted that a profile of the roller 734 may conform to the curvature of the windshield 100 so that the optical film 102 can be pressed against the windshield 100.

As shown in FIG. 8, as the roller 734 travels from the first edge 114 towards the second edge 116, in the direction “Dl”, the roller 734 applies the pressure on the optical film 102 for laminating the optical film 102 to the windshield 100. In one example, the pressure at which the roller 734 contacts the optical film 102 may lie between 200 kPa and 300 kPa. It should be noted that the roller mechanism 732 may be actuated hydraulically, mechanically, or pneumatically, as per application requirements. In some examples, the system 700 may omit the roller mechanism 732. In such examples, the pressing mechanism may be adapted to apply the pressure on the clamping arrangement 702 or the support structure 730 in order to press the optical film 102 and the windshield 100 against each other.

Further, in one example, the optical film 102 is laminated to the windshield 100 in a vacuum environment. In such an example, the system 700 may be enclosed in a vacuum chamber (not shown). Moreover, a pressure in the vacuum chamber may be dropped to a suitable level, such as 0.1 Pa, during the lamination process. Such a technique may reduce trapping of air between the optical film 102 and the windshield 100.

FIG. 9 illustrates a flowchart for a method 900 of laminating the optical film 102 to the windshield 100. The optical film 102 includes the optically clear adhesive 122 disposed on the bottom surface 112 thereof. The method 900 will be explained in relation to the system 200. However, the method 900 is applicable to the systems 600, 700 without any limitations.

At step 902, the method 900 includes holding the optical film 102 along the outer periphery 108 thereof using the clamping arrangement 202 including the plurality of clamps 204, 206, 208, 210. Further, each of the plurality of clamps 204, 206, 208, 210 is adapted to apply the tension on the optical film 102. In an example, the method 900 includes increasing the tension applied on the optical film 102 by each of the plurality of clamps 204, 206, 208, 210 upon contact of the optical film 102 with the windshield 100. Moreover, the method 900 also includes increasing the temperature of the optical film 102 using the heating module 226.

At step 904, the method 900 includes supporting the windshield 100 on the fixture 228 including the support structure 230. Further, the shape of the upper surface 232 of the support structure 230 is similar to the shape of the windshield 100. At step 906, the method 900 includes moving at least one of the clamping arrangement 202 and the support structure 230 using the pressing mechanism 224 to provide contact between the optical film 102 and the windshield 100 such that the optical film 102 conforms to the shape of the windshield 100 based on the tension applied on the optical film 102. Further, the optically clear adhesive 122 is adapted to bond the optical film 102 with the windshield 100.

In one embodiment, the method 900 further includes moving the clamping arrangement 202 towards the support structure 230 in order to press the optical film 102 against the windshield 100 and keeping the support structure 230 stationary. In another example, the method 900 further includes moving the support structure 630 towards the clamping arrangement 602 in order to press the windshield 100 against the optical film 102 and keeping the clamping arrangement 602 stationary. Further, in some examples, the optical film 102 is laminated to the windshield 100 in the vacuum environment.

The method 900 and system 200, 600, 700 described herein may provide an effective and easy to incorporate solution for laminating the optical film 102 coated with the optically clear adhesive 122 to the windshield 100. Further, the method 900 and system 200, 600, 700 for lamination described in this disclosure may eliminate buckling of the optical film 102 during the lamination of the windshield 100 and may allow easy conformance of the optical film 102 to the shape of the windshield 100. Further, the application of the present disclosure may be extended to lamination of window combiner films to windshields as the method 900 and system 200, 600, 700 described herein may allow complete wet out of window combiner films on windshield glasses, without buckling from the curves.

Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this disclosure be limited only by the claims and the equivalents thereof.

Claims

What is claimed is:

1. A system for laminating an optical film to a windshield, the optical film having an optically clear adhesive disposed on a bottom surface thereof, the system comprising: a clamping arrangement including a plurality of clamps for holding the optical film along an outer periphery thereof, wherein each of the plurality of clamps is adapted to apply a tension on the optical film; a fixture including a support structure for supporting the windshield thereon, wherein a shape of an upper surface of the support structure is similar to a shape of the windshield; and a pressing mechanism adapted to provide contact between the optical film and the windshield such that the optical film conforms to the shape of the windshield based on the tension applied on the optical film, wherein the optically clear adhesive is adapted to bond the optical film with the windshield.

2. The system of claim 1, wherein the pressing mechanism is further adapted to move the clamping arrangement towards the support structure in order to press the optical film against the windshield.

3. The system of claim 2, wherein the pressing mechanism is further adapted to press the optical film against the windshield with a pressure from about 10 kPa to about 1000 kPa.

4. The system of claim 1, wherein the pressing mechanism is further adapted to move the support structure towards the clamping arrangement in order to press the windshield against the optical film.

5. The system of claim 4, wherein the pressing mechanism is further adapted to press the windshield against the optical film with a pressure from about 10 kPa to about 1000 kPa.

6. The system of claim 1 , wherein the clamping arrangement is further adapted to apply a maximum tension of about 100 MPa on the optical film.

7. The system of claim 1 further comprising a heating module for increasing a temperature of the optical film.

8. The system of claim 1, wherein the clamping arrangement is further adapted to increase the tension applied on the optical film by each of the plurality of clamps upon contact of the optical film with the windshield.

9. The system of claim 1, wherein the pressing mechanism includes at least one of a hydraulic press and a mechanical press.

10. The system of claim 1 further comprising a roller mechanism adapted to apply a pressure on the optical film for laminating the optical film to the windshield.

11. The system of claim 10, wherein the roller mechanism further comprises at least one roller, the at least one roller contacting the optical film with a pressure from about 10 kPa to about 1000 kPa.

12. The system of claim 1, wherein the pressing mechanism is further adapted to establish a first point of contact between the optical film and the windshield based on a contact of a central portion of the optical film with a central portion of the windshield.

13. The system of claim 1, wherein the pressing mechanism is further adapted to establish a first point of contact between the optical film and the windshield based on a contact of an edge of the optical film with an edge of the windshield.

14. The system of claim 1, wherein the optical film is laminated to the windshield in a vacuum environment.

15. A method of laminating an optical film to a windshield, the optical film having an optically clear adhesive disposed on a bottom surface thereof, the method comprising: holding the optical film along an outer periphery thereof using a clamping arrangement including a plurality of clamps, wherein each of the plurality of clamps is adapted to apply a tension on the optical film; supporting the windshield on a fixture including a support structure, wherein a shape of an upper surface of the support structure is similar to a shape of the windshield; and moving at least one of the clamping arrangement and the support structure using a pressing mechanism to provide contact between the optical film and the windshield such that the optical film conforms to the shape of the windshield based on the tension applied on the optical film, wherein the optically clear adhesive is adapted to bond the optical film with the windshield.

16. The method of claim 15 further comprising: moving the clamping arrangement towards the support structure in order to press the optical film against the windshield; and keeping the support structure stationary.

17. The method of claim 15 further comprising: moving the support structure towards the clamping arrangement in order to press the windshield against the optical film; and keeping the clamping arrangement stationary.

18. The method of claim 15 further comprising increasing a temperature of the optical film using a heating module.

19. The method of claim 15 further comprising increasing the tension applied on the optical film by each of the plurality of clamps upon contact of the optical film with the windshield.

20. The method of claim 15 further comprising laminating the optical film to the windshield in a vacuum environment.

21. A system for laminating an optical film to a windshield, the optical film having an optically clear adhesive disposed on a bottom surface thereof, the system comprising: a clamping arrangement including a plurality of clamps for holding the optical film along an outer periphery thereof, wherein each of the plurality of clamps is adapted to apply a tension on the optical film; a fixture including a support structure for supporting the windshield thereon, wherein a shape of an upper surface of the support structure is similar to a shape of the windshield; and a pressing mechanism adapted to provide contact between the optical film and the windshield such that the optical film conforms to the shape of the windshield based on the tension applied on the optical film, wherein the optically clear adhesive is adapted to bond the optical film with the windshield, and wherein the pressing mechanism is adapted to provide contact between the optical film and the windshield based on a movement of at least one of the clamping arrangement and the support structure.

22. The system of claim 21 further comprising a heating module for increasing a temperature of the optical film.