WO2024003345A1

WO2024003345A1 - Laminated glazing with independent chambers

Info

Publication number: WO2024003345A1
Application number: PCT/EP2023/067986
Authority: WO
Inventors: Natalia Andrea RUEDA GUERRERO; Daniel ESTRADA DIAGO; Mauricio SALAZAR ASTETE; Andrés Fernando SARMIENTO; Juan Felipe CASTRO LANDINEZ; Mario Alfredo MACIAS MARTINEZ; Katherine del Rosario TOFEÑO HERRERA; Noelia Melissa CABRERA ROMERO
Original assignee: Agp Worldwide Operations Gmbh
Priority date: 2022-06-30
Filing date: 2023-06-30
Publication date: 2024-01-04

Abstract

The present invention falls in the field of automotive laminated glazing and relates to a laminated glazing comprising a plurality of independent chambers enhancing quality and manufacturing time.

Description

LAMINATED GLAZING WITH INDEPENDENT CHAMBERS

DESCRIPTION

FIELD OF THE INVENTION

PRIOR ART

Laminated glazing or laminated glass are known in the art as two or more distinct glass layers which are permanently bonded by plastic adhesives. These laminated products are, for instance, reinforced when compared to ordinary single pane of glass. Also, laminated glass are well known for being resistant to impacts and avoid shattering in the event of breakage, which makes them safer for the consumer.

The most common fields of application for laminated glazing are architecture, automobile safety, photovoltaic and ultraviolet protection.

Laminated glass are commonly implemented in the form of two glass layers bonded together but can also be comprised of more than two layers of glass. However, a laminated glass with two glass layers is preferred for its reduced thickness and weight compared to laminated glass having more than two glass layers and also for its convenience when adapted to automotive applications such as roofs, windshields etc.

One of the technical fields with a more intensive development is the implementation of methods for manufacturing laminated glazing using optical bonding adhesives and adapting it to most common applications such as automotive roofs, windshields, etc.

Conventional automotive lamination is carried out by using Optical Clear Adhesives (OCAs) that are already cured solid plastic bonding interlayers disposed in between glass layers. By heating, the solid interlayer softens and bonds to the glass layers. Pressure is conventionally applied such as by pinch rollers or by applying vacuum in autoclave cycles to ensure an appropriate bonding.

However, there exists a series of drawbacks in the conventional lamination methods when laminating automotive glazing with high curvature shapes since said high curvature shapes adds complexity in the processing of materials in between the two glass layers of a laminated glazing product. Optical distortion is a huge drawback since deairing is compromised. The solid plastic bonding layers disposition is also challenging since they tend to fold or wrinkle when placed on high curvature glass surfaces which makes it difficult to guarantee a uniform bonding between layers. The prior art W02020003252 has recently demonstrated the use of Liquid Optically Clear Adhesives (LOCAs) as a bonding element for high complexity curvature glazing, particularly containing active films. This solution has been showing desirable bonding results providing a glazing with excellent optical quality. The main drawback of applying a Liquid Optically Clear Adhesive in large glazing is known to be time consuming when compared to the cycle of the industrial production of laminated glazing.

In most cases, the LOCA application is made through injection but laminated glazing are stacks presenting complex formation and several layers of materials, which may result in poor quality of adhesive flow when injected inside the laminated glazing.

Therefore, it would be highly desirable to find injecting bonding methods and resulting products which provide a higher quality of adhesive flow during the injecting process and present an enhanced injection time in order to improve manufacturing steps of a laminated glazing.

DESCRIPTION OF THE INVENTION

The present invention provides a solution for the above mentioned issues by a laminated glazing according to independent claim 1 , a vehicle roof or window according to claim 14 and a method for manufacturing a laminated glazing according to independent claim 15. In dependent claims, preferred embodiments of the invention are defined.

In a first inventive aspect, the present invention provides a laminated glazing comprising: at least two glass layers comprising: a first glass layer having an exterior surface oriented towards the outside of the laminated glazing, an interior surface oriented towards the inside of the laminated glazing and an edge surface, and a second glass layer having an interior surface oriented towards the inside of the laminated glazing, an exterior surface oriented towards the outside of the laminated glazing and an edge surface, at least one plastic bonding layer having a length Lj, a width Wj and edges, and in contact with the interior surface of the first glass layer, an active film, having edges, a width w_f and a length L_f, wherein the length L_f is smaller than the length Lj, and the width w_f is smaller than the width Wj, a first spacing means located between said at least one plastic bonding layer and the active film, the first spacing means being arranged to form a gap between the at least one plastic bonding layer and the active film, a second spacing means located between said at least one plastic bonding layer and the interior surface of the second glass layer, and third spacing means located between at least a portion of the active film and the second glass layer, wherein the first, second and third spacing means are arranged to form a plurality of chambers, and the gap and the plurality of chambers are filled with at least one curable liquid optically clear adhesive.

The following terminology is used along the whole document to describe features of the invention.

The meaning of “layer”, as used in this context, shall include the common definition of the word: a sheet, quantity, or thickness, of material, typically of some homogeneous substance.

The term “glass” can be applied to many organic and inorganic materials, including many that are not transparent. From a scientific standpoint, “glass” is defined as a state of matter comprising a non-crystalline amorphous solid that lacks the ordered molecular structure of true solids. Glasses have the mechanical rigidity of crystals with the random structure of liquids. A “glazing” is a product comprised of at least one layer of a transparent material, preferably glass, which serves to provide for the transmission of light and/or to provide for viewing of the side opposite to the viewer and which may be mounted in an opening in a building, vehicle, wall or roof or other framing member or enclosure.

“Laminates”, in general, are products comprised of multiple sheets of thin, relative to their length and width, material, with each thin sheet having two oppositely disposed major faces and typically of relatively uniform thickness, which are permanently bonded to one and other across at least one major face of each sheet.

An active film is a dynamic layer presenting changes of one or more properties based on an external input.

The term “stack” refers to the arrangement in a pile manner of a plurality of layers.

An element referred as being located “between layers” in a stack does not limit or necessarily implies that said element is in direct contact with these layers.

The present invention provides a laminated glazing comprising at least two glass layers, at least one plastic bonding layer, an active film, a first spacing means, a second spacing means and a third spacing means.

The at least one plastic bonding layer is in contact with the interior surface of the first glass layer. Even though the at least one plastic bonding layer is in contact with the interior surface of the first glass layer, an interlayer, such as a coating, could be located in between the first glass layer and the at least one plastic bonding layer, which is considered as an indirect contact of the at least one plastic bonding layer with the first glass layer.

The interior surface of the first glass layer should be understood as the surface of the first glass layer oriented towards the at least one plastic bonding layer, whereas the exterior surface of the first glass layer is the opposed surface.

The active film is separated from the at least one plastic bonding layer by the first spacing means. That is, a first surface of the active film is oriented towards the first glass layer and this first surface is the one in contact with the first spacing means. The active film has a length L_f smaller than the length L; of the at least one plastic bonding layer and a width Wf smaller than the width w_t of the at least one plastic bonding layer.

The first spacing means are arranged to form a gap between the at least one plastic bonding layer and the active film. Said gap is filled with a curable liquid optically clear adhesive (“LOCA”).

The second spacing means are located between the at least one plastic bonding layer and the interior surface of the second glass layer.

The interior surface of the second glass layer should be understood as the surface of the second glass layer oriented towards the at least one plastic bonding layer, whereas the exterior surface of the second glass layer is the opposed surface.

The third spacing means are located between at least a portion of the active film and the second glass layer. The third spacing means are in contact with the second surface of the active film, i.e. the surface of the active film oriented towards the second glass layer and opposed to the first surface. In an embodiment, the third spacing means can also be in contact with at least a portion of the at least one plastic bonding layer.

The first, second and third spacing means are arranged to form a plurality of independent chambers, wherein the plurality of chambers are filled with at least one curable liquid optically clear adhesive. Said chambers are isolated from one another.

Advantageously, by forming a plurality of independent chambers in between layers of the laminated glazing helps breaking down complex areas due to glass curvature, reduces the volume to be filled by dividing said volume in sub sections and occupying part of said volume with first, second and third spacing means and, finally, ensures that no changes are performed in the cross sections of the laminated glazing by dividing said volume in a plurality of chambers. Also, by dividing the volume to be filled in a plurality of chambers using the first, second and third spacing means, said plurality of chambers can be filled independently at the same time and, therefore, the time implemented for filling said volume is significantly reduced. Additionally, the present invention avoids air trapping inside of the laminate in between layers by dividing the volume to be filled in a plurality of smaller volumes.

In an embodiment, the edges of the at least one plastic bonding layer and the edges of the first glass layer are substantially aligned.

In an embodiment, the first spacing means is configured as at least one wall.

In an embodiment, the first spacing means are located substantially at the perimeter of the active film.

In an embodiment, the first spacing means is placed extending along the whole perimeter of the active film.

In an embodiment, the gap has a thickness between 0,1 to 6,0 mm.

In an embodiment, at least one chamber has a thickness between 0,1 to 6,0 mm.

In an embodiment, the laminated glazing comprises a plurality of active films, each active film having a width smaller than the width of the at least one plastic bonding layer, wherein the sum of the lengths of the active films is smaller than the length of the at least one plastic bonding layer, wherein the first spacing means is located between the at least one plastic bonding layer and the active films, the first spacing means being arranged to form a respective gap between the at least one plastic bonding layer and each active film. Said gaps are filled with a curable liquid optically clear adhesive.

In an embodiment, the edges of the at least one plastic bonding layer and the edges of the second glass layer are substantially aligned.

In an embodiment, the second spacing means are placed substantially at the perimeters of both the at least one plastic bonding layer and the second glass layer.

In an embodiment, the second spacing means extends along the length and the width of the plastic bonding layer and the interior surface of the second glass layer. ln an embodiment, the second spacing means is configured as at least one wall.

In an embodiment, the second spacing means is one wall. In other embodiment, the second spacing means are two independent walls.

In an embodiment, the third spacing means is configured as at least one wall.

In an embodiment, the third spacing means is located along at least part of the length and at least part of the width of the second glass layer and a portion of said third spacing means is in contact with the second side of the active film.

In some preferred embodiments, no additional glass layer other than the first glass layer and the second glass layer is comprised in the laminated glazing.

In an embodiment, at least one plastic bonding layer is a thermoplastic layer.

In an embodiment, the length L; of the at least one plastic bonding layer is substantially equal to the length of the first glass layer.

In an embodiment, at least one plastic bonding layer is selected from the group of Polyvinyl Butyral (PVB), Ethylene-vinyl acetate (EVA), or Thermoplastic polyurethane (TPU).

In an embodiment, the plastic bonding layer is a PVB and, more preferably, the PVB layer presents enhanced ultraviolet protection properties.

In an embodiment where the PVB is a PVB with enhanced ultraviolet protection properties, ultraviolet protection properties allows below 0,05% of light transmission in the range from 280 to 385 nm and allows below 5% of light transmission at 405 nm.

In an embodiment, the plastic bonding layer has the same area as the glass layers.

In an embodiment, the laminated glazing has at least three chambers. Advantageously, the more chambers are formed in between the first, second and third spacing means, the more the volume is divided and, thus, the quicker said volume can be filled by filling all formed chambers at the same time.

In an embodiment, the at least one plastic bonding layer comprises a plurality of plastic bonding layers.

In an embodiment, the plurality of plastic bonding layers comprises at least two plastic bonding layers having at least one different property, such as a first plastic bonding layer configured for ultraviolet (UV) blocking and a second plastic bonding layer configured for infrared (IR) blocking.

In an embodiment, the laminated glazing comprises one or more additional layers including, but not limited to, interlayers, coatings and/or films.

In an embodiment, the laminated glazing comprises at least one additional interlayer in contact with the interior surface of the second glass layer wherein: the second spacing means are located between the at least one plastic bonding layer and the at least one additional interlayer, and the third spacing means are located between at least a portion of the active film and the at least one additional interlayer.

In that embodiment, the second spacing means are located between the at least one plastic bonding layer and the at least one additional interlayer; preferably, at the perimeter of both of these layers.

In an embodiment, the at least one additional interlayer is a plastic bonding layer. Advantageously, having an additional interlayer being a plastic bonding layer in the laminated glazing provides enhanced mechanical strength to the laminated glazing.

In preferred embodiment, the additional interlayer is a PVB.

In an embodiment, the at least one additional interlayer comprises a plurality of additional interlayers. ln an embodiment, the at least one additional interlayer is a stack comprising one or more plastic bonding layers and/or performance coatings. A performance coating is a coating configured to provide a function such as solar control, heating control, color appearance, etc. In a particular embodiment, the at least one additional interlayer is a stack comprising one or more plastic bonding layers and/or an interlayer selected from the list of: PET (Polyethylene Terephthalate), COP (Cyclic Olefin Polymer), PP (Polypropylene), PC (polycarbonate), PI (polyimide), PA (polyamide), PS (Polystyrene), PEN (Polyethylene Naphthalate), TAC (Triacetate Cellulose) and/or performance coatings.

In an embodiment, the interior surface of the first glass layer and/or the exterior surface of the second glass layer has an anti reflective coating.

In an embodiment, the interior surface of the first glass layer and/or the exterior and/or the interior surface of the second glass layer has a solar control coating.

In an embodiment, the interior and/or the exterior surface of the first glass layer and/or the exterior and/or the interior surface of the second glass layer has a heating coating.

The gap and the chambers can be filled either with the same or different curable liquid optically clear adhesives.

In an embodiment, the gap is filled with a first curable liquid optically clear adhesive and at least one of the plurality of chambers is filled with a second curable liquid optically clear adhesive, the second curable liquid optically clear adhesive being different from the first curable liquid optically clear adhesive. In this embodiment, at least another chamber may be filled with the first curable liquid optically clear adhesive, with the second curable liquid optically clear adhesive or with a third curable liquid optically clear adhesive.

In an embodiment, the first, the second and/or the third curable liquid optically clear adhesives are different in composition, viscosity and/or transparency.

In an embodiment, the first curable liquid optically clear adhesive has a different viscosity than the second curable liquid optically clear adhesive. In an embodiment, the first curable liquid optically clear adhesive has a lower viscosity than the second curable liquid optically clear adhesive.

In an embodiment, the first curable liquid optically clear adhesive has a viscosity between 100 centipoises and 1500 centipoises, and the second curable has a viscosity between 100 centipoises and 500 000 centipoises.

In a particular embodiment, the first curable liquid optically clear adhesive has a viscosity between 100 centipoises and 500 centipoises, and the second curable has a viscosity between 100 centipoises and 300 000 centipoises.

The materials and/or properties of the first, second and/or third spacing means can be the same or different.

In an embodiment, the first, second and/or third spacing means has a viscosity above 50 000 centipoises

In an embodiment, the first, second and/or third spacing means are made of high viscosity curable viscoelastic polymer. In this context, high viscosity should be understood as above 50 000 centipoises. Furthermore, the viscosity of the first, second and/or third spacing means is higher than the viscosity of the at least one curable liquid optically clear adhesive.

In an embodiment, the first, second and/or third spacing means are made of a plastic interlayer selected from the list of PVB, EVA, TPU, POE (Polyolefin elastomers) or a combination thereof.

In an embodiment, the first glass layer and/or the second glass layer have a surface compressive strength greater than or equal to 2 MPa, preferably between 8 MPa and 300 MPa, more preferably between 35 MPa and 300 MPa.

In an embodiment, the first glass layer and/or the second glass layer are selected from the group of Soda-lime, Borosilicate or Aluminosilicate glass.

In an embodiment, the thickness of the first glass layer and/or the second glass layer are in the range of 0,5 mm to 5 mm.

In an embodiment, the first and the second glass layers are curved.

In an embodiment, the active film comprises at least one liquid crystal, at least one suspended particle device, at least one polymer dispersed liquid crystal, , at least one electrochromic layer, at least one Polymer Network Liquid Crystal, at least one touch capacitive layer, at least one holographic film, at least one LED, at least one embedded light fiber, at least one heater defroster, at least one sensor, at least one antenna and/or other electrical device.

In the particular case of the active film being a liquid crystal film, an electricity input provides to the active film the ability to switch its light transmission.

In the particular case of the active film being a touch capacitive layer, the active film can change its capacitance and trigger another element when receiving an external input which closes the circuit, such as by touching the surface of the laminated glazing.

In the particular case of the active film being a holographic film, this is a film that normally changes the polarization of light and reflects images projected by a projector.

In a further embodiment, the laminated glazing comprises at least a performanceenhancing chamber, preferably a hidden chamber, filled with an adhesive to enhance the mechanical performance of the laminated glazing, in particular the laminate glazing adherence. Advantageously, when the at least performance-enhancing chamber is a hidden chamber, the adhesive used for filling can be non-transparent. In a particular embodiment, the adhesive used for filling the performance-enhancing chamber has a storage modulus greater than 6000 Pa, preferably over 2 MPa.

In a particular embodiment, the at least performance-enhancing chamber is located under a black print of the marginal edges of the glazing. This type of black prints helps for hiding purposes, particularly hide electrical connections, fixing means such as glue for fixing the glazing to a car body and transitions in between layers of the laminated glazing. In a second inventive aspect, the present invention provides a vehicle roof or a vehicle window comprising a laminated glazing according to any one of the embodiments of the first inventive aspect.

In a third inventive aspect, the present invention provides a method for manufacturing a laminated glazing according to any of the embodiments of the first inventive aspect, the method comprising the following steps: a) placing at least one plastic bonding layer on the interior surface of a first glass layer, b) placing a non-adhesive plastic interlayer on the surface of the at least one plastic bonding layer not in contact with the first glass layer, c) placing the interior surface of a second glass layer onto the surface of the non- adhesive plastic interlayer not in contact with said at least one plastic bonding layer, d) laminating with heat and pressure the product resulting from the previous step, e) removing the non-adhesive plastic interlayer and the second glass layer, forming a first pre-assembly, f) arranging an active film spaced from the surface of the at least one plastic bonding layer of the first pre-assembly, wherein the active film is spaced from said at least one plastic bonding layer by first spacing means such that a gap is formed, g) filling the gap in between the at least one plastic bonding layer and the active film with a curable liquid optically clear adhesive, h) curing the product resulting from the previous step, i) placing the second spacing means onto the at least one plastic bonding layer and the third spacing means onto at least a portion of the active film, j) placing the second glass layer onto the product resulting from the previous step, such that the second spacing means is arranged between the at least one plastic bonding layer and the interior surface of the second glass layer and the third spacing means is arranged between at least a portion of the active film and the second glass layer, wherein the first, second and third spacing means are arranged to form a plurality of chambers, wherein the exterior surface of the second glass layer is oriented towards the outside of the laminated glazing, k) filling the plurality of chambers with at least one curable liquid optically clear adhesive, I) curing the product resulting from the previous step.

Advantageously, placing a non-adhesive plastic interlayer in step b) allows to remove in step e) said non-adhesive plastic interlayer and the second glass layer after laminating with heat and pressure in step d) without damaging any of the first glass layer or the plastic bonding layer.

In an embodiment, the gap is filled with a first curable liquid optically clear adhesive and at least one of the chambers formed by the first, second and third spacing means are filled with a second liquid optically clear adhesive, the second curable liquid optically clear adhesive being different form the first curable liquid optically clear adhesive. In this embodiment, at least another chamber may be filled with the first curable liquid optically clear adhesive, with the second curable liquid optically clear adhesive or with a third curable liquid optically clear adhesive.

In an embodiment, the first curable liquid optically clear adhesive has a different viscosity than the second curable liquid optically clear adhesive.

In an embodiment of the third inventive aspect, in step d), the laminating is made by autoclave cycle or pinch rollers.

Autoclave cycle operates with a combination of high temperature, high pressure and time in order to provide a product with specific properties.

Pinch rollers are rubberized spinning wheels used to press a plurality of sheets together and form a laminated product by creating friction.

In an embodiment, the gap is filled with a curable liquid optically clear adhesive by injection through the first spacing means.

In an embodiment of the third inventive aspect, the curing of steps h) and I) are made by UV light curing, platinum curing, moisture curing, thermal curing, catalyst curing or room temperature curing.

In an embodiment of the third inventive aspect, step f) comprises forming a second preassembly by arranging the first spacing means on the active film and curing, wherein the second pre-assembly is placed onto the surface of the at least one plastic bonding layer of the first pre-assembly.

To create a second pre-assembly comprising the first spacing means and the active film eases the step of placing the first spacing means on the first plastic bonding layer on the required portion of said first plastic bonding layer and of the active film.

In an embodiment, the method comprises bending the first and second glass layers to a desired curved shape before the laminating step. In this embodiment, the first glass layer provided in step a) and the second glass layer provided in step c) have a curved shape and the laminated glazing obtained as a result of the manufacturing process also has a curved shape.

In an embodiment, the first, second and/or third spacing means are made of high viscosity curable viscoelastic polymer.

In an embodiment, the first, second and/or third spacing means are made of a plastic interlayer selected from the list of PVB, EVA, TPU, POE or a combination thereof.

In an embodiment, the method comprises at least one additional step for curing the first, second and/or third spacing means. In an embodiment, curing of the first spacing means is performed before step g). In an embodiment, curing of the second and/or third spacing means is performed before step k).

All the features described in this specification (including the claims, description and drawings) can be combined in any combination, with the exception of combinations of mutually exclusive features and/or steps.

DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the invention will be seen more clearly from the following detailed description of a preferred embodiment provided only by way of illustrative and non-limiting example in reference to the attached drawings.

Figures 1 a-1 e These figures show steps of the method for manufacturing a laminated glazing according to an embodiment of the invention.

Figures 2a-2h These figures show steps of the method for manufacturing a laminated glazing according to an embodiment of the invention.

Figure 3 This figure shows a schematic cross section of a laminated glazing according to an embodiment of the invention.

Figure 4 This figure shows a schematic cross section of a laminated glazing according to an embodiment of the invention.

Figure 5 This figure shows a schematic cross section of a laminated glazing according to an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a product or a method.

Figures 1a to 1e and 2a to 2h depict steps of the method for manufacturing a laminated glazing (10) according to an embodiment of the present invention.

The steps of the method according to the present invention are sequenced as follows: a) Placing at least one plastic bonding layer (2) on the interior surface of a first glass layer (1). b) Placing a non-adhesive plastic interlayer (3) on the surface of the at least one plastic bonding layer (2) not in contact with the first glass layer (1), c) Placing the interior surface of a second glass layer (4) onto the surface of the non-adhesive plastic interlayer (3) not in contact with said at least one plastic bonding layer (2). d) Laminating with heat and pressure the product resulting from the previous step, e) Removing (R) the non-adhesive plastic interlayer (3) and the second glass layer (4), forming a first pre-assembly. f) Arranging an active film (6) spaced from the surface of the at least one plastic bonding layer (2) of the first pre-assembly, wherein the active film (6) is spaced from said at least one plastic bonding layer (2) by first spacing means (5) such that a gap (G) is formed. g) Filling the gap (G) in between the at least one plastic bonding layer (2) and the active film (6) with a curable liquid optically clear adhesive. h) Curing the product resulting from the previous step. i) Placing second spacing means (7) onto the at least one plastic bonding layer (2) and third spacing means (8) onto at least a portion of the active film (6). j) Placing the second glass layer (4) onto the product resulting from the previous step, such that the second spacing means (7) is arranged between the at least one plastic bonding layer (2) and the interior surface of the second glass layer (4) and the third spacing means (8) is arranged between at least a portion of the active film (6) and the second glass layer (4), wherein the first (5), second (7) and third (8) spacing means are arranged to form a plurality of chambers (C), wherein the exterior surface of the second glass layer (4) is oriented towards the outside of the laminated glazing (10). k) Filling the plurality of chambers (C) with at least one curable liquid optically clear adhesive. l) Curing the product resulting from the previous step.

In particular, Figure 1a shows the product resulting from step c) of the method according to the present invention.

In the example of the embodiment depicted in Figures 1a to 1e and 2a to 2h, the product resulting from step c), and the laminated glazing (10) resulting from the last step of the method, comprises only one plastic bonding layer (2).

In a particular example, the plastic bonding layer (2) of the stack of Figure 1a, and thus of the resulting laminated glazing (10), comprises a PVB, more preferably PVB with enhanced ultraviolet protection properties. Also in the particular example from Figures 1a to 1e and 2a to 2h, the laminated glazing has two glass layers, namely a first glass layer (1) and a second glass layer (4).

Figure 1 b schematically depicts the autoclave cycle (A) from step d) of the method of the present invention, which comprises laminating the stack shown in Figure 1a with heat and pressure in order to cure the plastic bonding layer (2). By laminating the stack from Figure 1a presenting the non-adhesive plastic interlayer (3), step e) of the method is achievable since said non-adhesive plastic interlayer (3) allows, as shown in Figure 1c, the removal (R) both of the non-adhesive interlayer (3) and the second glass layer (4) from the plastic bonding layer (2) of the stack from Figure 1a and 1b. When a laminated glazing having curved glass layers is desired, bending the first and second glass layers to the desired shape should be carried out before starting the lamination process.

The resulting products from step e) are the separated second glass layer (4) and a first pre-assembly, wherein the first pre-assembly comprises the first glass layer (1) and the plastic bonding layer (2) bonded together. In figure 2a the first pre-assembly is shown in a top view, wherein the plastic bonding layer (2) is visible and the first glass layer (1), bonded to the plastic bonding layer (2) is hidden by the plastic bonding layer (2).

In Figure 1 d, step f) of the method is shown, said step f) of the method comprising arranging an active film (6) spaced from the surface of the plastic bonding layer (2) of the first pre-assembly. As shown, the active film (6) is spaced from the plastic bonding layer (2) by first spacing means (5), forming a gap (G).

In particular examples of Figure 1 d, the first spacing means (5) is embodied as a wall extending along the perimeter of the active film (6), delimiting the gap (G).

In some particular examples, as shown in Figure 2b to 2h, the laminated glazing comprises a plurality of active films (6), preferably separated one from the other, and arranged along the length L_f which is the total length available for placing the active film(s) (6). In the embodiment of Figure 2 two active films (6) are shown. However, in other embodiments a different number of active films (6) may be present in the laminated glazing. ln some preferred examples of the method, before step f), the first spacing means (5) are placed on the active film (6) before placing this arrangement on the plastic bonding layer (2). This is shown in Figure 2b, which shows the two active films (6), each having a first spacing means (5) placed on a first surface of the active films, the first spacing means (5) embodied in this figure as a wall extending along the perimeter of the active films (6).

Figure 2c shows step f) of the method, wherein the active films (6) have been arranged (2) spaced from the surface of the plastic bonding layer (2) by the first spacing means (5). In figure 2c, the first surface of the active films (6) where the first spacing means (5) are placed is oriented towards the plastic bonding layer (2), and thus the opposed surface of the active films (6) (namely, the second surface) is visible in the figure.

In an embodiment, the first spacing means (5) is made of curable viscoelastic polymer and the method comprises an additional step of curing the first spacing means (5). When the hardening of the first spacing means (5) is completed, the active film (6) and the plastic bonding layer (2) are bonded.

In the example shown in Figure 2c, the active films (6) have substantially the same length and substantially the same width and the total length of the two active films (6) is smaller than the length of the first glass layer (1) and the length of the plastic bonding layer (2).

Then, during step g) of the method, the gap (G), located in between the plastic bonding layer (2) and the active film (6), is filled with a first curable liquid optically clear adhesive.

In preferred examples of the method, the gap (G) is filled by injecting the first curable liquid optically clear adhesive. More preferably, the first curable liquid optically clear adhesive is injected passing through the first spacing means (5). This is schematically shown in figure 2d.

Step h) of the method, which is not represented in the set of Figures, comprises curing the product resulting from step g). After the curing of step g), the first curable liquid optically clear adhesive is in solid state.

In some preferred examples, the curing of step g) is made by UV light curing, platinum curing, moisture curing, thermal curing, catalyst curing or room temperature curing. Figures 2e and 2f show step i) of the method, which comprises placing second spacing means (7) onto the at least one plastic bonding layer (2) and third spacing means (8) onto at least a portion of the active film (6). In the embodiment shown, the second spacing means (7) and the third spacing means (8) are embodied as walls. In an example, as shown in Figure 2e, in step i), the second spacing means (7) are placed substantially at the perimeter of the plastic bonding layer (2), preferably along the whole perimeter. As visible in Figure 2f, the third spacing means (8) is provided along a length of the plastic bonding layer (2) and on a portion of the active films (6). The second spacing means (7) and the third spacing means (8) are arranged such that they define some boundaries which, in combination with the layers of the laminated glazing, define a plurality of independent chambers (C).

Figure 2g shows step j) of placing the second glass layer (4) onto the product resulting from step i). In this figure, the second glass layer (4) has been depicted as a semitransparent grey layer.

In some particular embodiments, not shown in Figure 2g, at least one additional interlayer can be placed in between the second glass layer (4) and the second (7) and third (8) spacing means. In said embodiments, the at least one additional interlayer is preferably laminated with the second glass layer (4) and the stack formed by the at least one additional interlayer and the second glass layer (4) is placed onto the product resulting from step i).

Figure 1e depicts a situation where steps i) to j) of the method of the invention have been performed.

It can be seen that the second spacing means (7) has been placed onto the plastic bonding layer (2) and the third spacing means (8) has been placed onto a portion of the active film (6) and onto a portion of the plastic bonding layer (2). Also, the second glass layer (4) has been placed onto the product resulting from step i), such that the second spacing means (7) is arranged between the plastic bonding layer (2) and the interior surface of the second glass layer (4) and the third spacing means (8) is arranged between at least a portion of the active film (6) and the second glass layer (4). In an embodiment, the second (7) and/or third (8) spacing means is made of curable viscoelastic polymer and the method comprises an additional step of curing the second (7) and/or third (8) spacing means which is performed before step k).

The plurality of chambers (C), defined by the first (5), second (7) and third (8) spacing means and the layers of the laminated glazing (10) are visible in Figures 1e and 2f. In the embodiment shown in Figure 2f, three chambers (C) are visible, namely a central chamber between the active film (6) and the second glass layer (4) and two side chambers between the plastic bonding layer (2) and the second glass layer (4). In other embodiments, the two side chambers are implemented as a single perimetric chamber.

In step k) of the method of the invention, the plurality of chambers (C) are filled with at least one curable liquid optically clear adhesive. This is schematically shown in Figure 2h. Advantageously, by having a plurality of independent chambers (C), the filling with curable liquid optically clear adhesive can be performed in parallel in the different chambers (C), thus resulting in a more efficient process.

In an embodiment, the central chamber is filled with a curable liquid optically clear adhesive different from the curable liquid optically clear adhesive with which the two side chambers or the perimetric chamber are filled.

In an embodiment, the central chamber is filled with the same curable liquid optically clear adhesive with which the gap is filled.

In some more preferred examples, the first spacing means (5) and at least a portion of the third spacing means (8) are aligned, as visible in Figure 1e.

Finally, the product resulting from step k) is cured in step I) of the method of the invention. After the curing of step I), the at least one curable liquid optically clear adhesive which fills the chambers (C) is in solid state.

In some preferred examples, not shown in the set of figures, the curing of step I) is made by UV light curing, platinum curing, moisture curing, thermal curing, catalyst curing or room temperature curing. Furthermore, the cured product resulting from step I) is a laminated glazing (10) according to one embodiment of the invention. Figure 3 depicts a laminated glazing (10) according to an embodiment of the invention. The laminated glazing (10) according to this embodiment comprises a first glass layer

(1) and two plastic bonding layers (2.1 , 2.2). In this specific embodiment, the first plastic bonding layer (2.1) is an infrared blocking layer in contact with the interior surface of the first glass layer (1) and the second plastic bonding layer (2.2) is an ultraviolet blocking layer in contact with the first plastic bonding layer (2.1). In another specific embodiment the second plastic bonding layer (2.2) are selected from the list of: PET, COP, PP, PC, PI, PA, PS, PEN, TAC.

In some other examples, the laminated glazing (10) has only one plastic bonding layer

(2), as shown in connection with figures 1 and 2, or more than two plastic bonding layers (2) and these plastic bonding layers may be performance coating layers providing functions to said layers such as solar control, heating control, color appearance shifting, etc.

In this specific example, at the perimeters of the first glass layer (1) and the first plastic bonding layer (2.1), a black print (B) is inserted on the interior surface of the first glass layer (1). Black print (B) helps for hiding purposes, particularly hide electrical connections, fixing means such as glue for fixing the glazing to a car body and transitions in between layers of the laminated glazing.

The first spacing means (5) is located on a portion of the layer of the plastic bonding layers (2.1 , 2.2) which is most distant from the first glass layer (1), which in the embodiment depicted in Figure 3 is the second plastic bonding layer (2.2) and at the perimeter of an active film (6). This arrangement forms a gap (g) in between the second plastic bonding layer (2.2) and the active film (6).

In some examples of the invention, the active film (6) comprises at least one liquid crystal, at least one suspended particle device, at least one polymer dispersed liquid crystal, at least one touch capacitive layer, at least one LED, at least one embedded light fiber, at least one heater defroster, at least one sensor, at least one antenna and/or other electrical devices.

The gap (G) is filled with a curable liquid optically clear adhesive. In the present embodiment depicted in Figure 3, the second spacing means (7) are located at least on a portion of the perimeter of the second plastic bonding layer (2.2) and at least on a portion of the perimeter of the second glass layer (4).

Also, the third spacing means (8) are located on the second surface of the active film (6), i.e. the surface opposed to the first surface where the first spacing means (5) are located. The third spacing means (8) are also in contact with at least a portion of the second glass layer (4).

Also preferably, the edges of the first glass layer (1) are substantially aligned with the edges of the second glass layer (2).

A plurality of chambers (C) are formed in between the first spacing means (5), the second spacing means (7) and the third spacing means (8). In the particular example of Figure 3, the laminated glazing (10) comprises three chambers (C). The chambers (C) are filled with at least one curable liquid optically clear adhesive.

In specific examples, the gap (G) is filled with a first curable liquid optically clear adhesive and at least one of the plurality of chambers (C) is filled with a second curable liquid optically clear adhesive. In an embodiment, the first curable liquid optically clear adhesive has a different viscosity than the second curable liquid optically clear adhesive.

In some particular examples of the invention, the first (5), second (7) and third (8) spacing means are made of a curable viscoelastic polymer having a higher viscosity than the at least one curable liquid optically clear adhesive.

In the particular example depicted in Figure 3, a black print (B) is placed at the perimeter of the exterior surface of the second glass layer (4), which is the surface oriented towards the outside of the laminated glazing.

In an embodiment, the first glass layer (1) and/or the second glass layer (4) are selected from the group of Soda-lime, Borosilicate or Aluminosilicate glass. In an embodiment, the thickness of the first glass layer (1) and/or the second glass layer (4) are in the range of 0,5 mm to 5 mm. In an embodiment of the invention, the interior surface of the first glass layer (1) and/or the exterior and/or the interior surface of the second glass layer (4) has a solar control coating.

In an embodiment of the invention, the interior and/or the exterior surface of the first glass (1) layer and/or the exterior and/or the interior surface of the second glass layer (4) has a heating coating.

In an embodiment, the first (1) and the second glass layers (4) are curved.

Figure 4 depicts a laminated glazing (10) according to another embodiment of the invention.

In Figure 4, the laminated glazing (10) comprises all the elements of the laminated glazing (10) of Figure 2 but further comprises an additional interlayer (9) in contact with the interior surface of the second glass layer (4).

In the specific embodiment of Figure 4, the second spacing means (7) are, thus, located at least at a portion of the perimeter of the second plastic bonding layer (2.2) and at least at a portion of the perimeter of the additional interlayer (9). Also, the third spacing means (8) extend along part of the length and a portion of the third spacing means (8) is located on the active film (6) and a portion of the additional interlayer (9).

Although one additional interlayer (9) is shown in Figure 4, in other embodiments the laminated glazing (10) comprises a plurality of additional interlayers (9). In some further examples, the at least one additional interlayer (9) is a plastic bonding layer.

In the present example depicted in Figure 4, the additional interlayer (9) is a thermoplastic interlayer, more preferably, a PVB, even more preferably, a PVB having enhanced UV protection properties.

In examples of the invention, the at least one plastic bonding layer (2) and the at least one additional interlayer (9) are selected from the group of a PVB, EVA, POE or TPU. In Figure 5, the laminated glazing (10) comprises all the elements of the laminated glazing (10) of Figure 4 but further comprises an additional interlayer (9.2) in contact with the interior surface of the additional interlayer (9).

In the specific embodiment of Figure 5, the second spacing means (7) are, thus, located at least at a portion of the perimeter of the second plastic bonding layer (2.2) and at least at a portion of the perimeter of the additional interlayer (9.2). Also, the third spacing means (8) extend along part of the length and a portion of the third spacing means (8) is located on the active film (6) and a portion of the additional interlayer (9.2).

In this same specific example, the laminated glazing (10) comprises at least a performance-enhancing chamber (D), preferably a hidden chamber, filled with an adhesive to enhance the mechanical performance of the laminated glazing (10), in particular the laminate glazing adherence. When the at least performance-enhancing chamber (D) is a hidden chamber, the adhesive used for filling can be non-transparent. Advantageously, the adhesive used for filling the performance-enhancing chamber (D) has a storage modulus greater than 6000 Pa, preferably over 2 MPa.

Further, the at least performance-enhancing chamber is located under the black print (B) of the marginal edges of the glazing (10). As said, this type of black prints helps for hiding purposes, particularly hide electrical connections, fixing means such as glue for fixing the glazing to a car body and transitions in between layers of the laminated glazing (10).

In the present example, either, the second plastic bonding layer (2.2) or the additional interlayer (9.2), or both, are selected from the list of: PET, COP, PP, PC, PI, PA, PS, PEN, TAC. These second plastic bonding layer (2.2) and the additional interlayer (9.2) prevent the diffusion effects between the the first plastic bonding layer (2.1) and the additional interlayer (9).

Claims

1.- A laminated glazing (10) comprising: at least two glass layers (1 , 4) comprising: a first glass layer (1) having an exterior surface oriented towards the outside of the laminated glazing (10), an interior surface oriented towards the inside of the laminated glazing (10) and an edge surface, and a second glass (4) layer having an interior surface oriented towards the inside of the laminated glazing (10), an exterior surface oriented towards the outside of the laminated glazing (10) and an edge surface, at least one plastic bonding layer (2) having a length

a width w_t and edges, and in contact with the interior surface of the first glass layer (1), an active film (6), having a length L_f, a width w_f and edges, wherein the length Lf is smaller than the length and the width w_f is smaller than the width w_{i t} a first spacing means (5) located between said at least one plastic bonding layer (2) and the active film (6), the first spacing means (5) being arranged to form a gap (G) between the at least one plastic bonding layer (2) and the active film (6), a second spacing means (7) located between said at least one plastic bonding layer (2) and the interior surface of the second glass layer (4), and third spacing means (8) located between at least a portion of the active film (6) and the second glass layer (4), wherein the first (5), second (7) and third (8) spacing means are arranged to form a plurality of chambers (C), and the gap (G) and the plurality of chambers (C) are filled with at least one curable liquid optically clear adhesive.

2.- The laminated glazing (10) according to the preceding claim, further comprising at least one additional interlayer (9) in contact with the interior surface of the second glass layer (4) wherein: the second spacing means (7) are located between the at least one plastic bonding layer (2) and the at least one additional interlayer (9), and the third spacing means (8) are located between at least a portion of the active film (6) and the at least one additional interlayer (9).

3.- The laminated glazing (10) according to the preceding claim, wherein the at least one additional interlayer (9) is a plastic bonding layer.

4.- The laminated glazing (10) according to any of the preceding claims, wherein the gap (G) is filled with a first curable liquid optically clear adhesive and at least one of the plurality of chambers (C) is filled with a second curable liquid optically clear adhesive.

5.- The laminated glazing (10) according to the preceding claim, wherein the first curable liquid optically clear adhesive has a different viscosity and/or a different transparency than the second curable liquid optically clear adhesive.

6.- The laminated glazing (10) according to any of the preceding claims, wherein the first (5), second (7) and/or third (8) spacing means are made of high viscosity curable viscoelastic polymer.

7.- The laminated glazing (10) according to any of the preceding claims, wherein the first glass layer (1) and/or the second glass layer (4) are selected from the group of Sodalime, Borosilicate or Aluminosilicate glass.

8.- The laminated glazing (10) according to any of the preceding claims, wherein the at least one plastic bonding layer (2) and/or the at least one additional interlayer (9) are selected from the group of a PVB, EVA, POE or TPU.

9.- The laminated glazing (10) according to any of the preceding claims, wherein the active film (6) comprises at least one liquid crystal, at least one suspended particle device, at least one polymer dispersed liquid crystal, at least one touch capacitive layer, at least one holographic film, at least one LED, at least one embedded light fiber, at least one heater defroster, at least one sensor, at least one antenna and/or other electrical device.

10.- The laminated glazing (10) according to any of the preceding claims, wherein the interior surface of the first glass layer (1) and/or the interior and/or exterior surface of the second glass layer (4) has a solar control coating.

11.- The laminated glazing (10) according to any of the claims 1 to 5, wherein the first (5), second (7) and/or third (8) spacing means are made of a plastic interlayer selected from the list of PVB, EVA, TPU, POE or a combination thereof.

12.- The laminated glazing (10) according to any of the preceding claims, wherein the laminated glazing (10) comprises at least a performance-enhancing chamber (D), preferably a hidden chamber, filled with an adhesive to enhance the mechanical performance of the laminated glazing,

13.- The laminated glazing according to claim 12, wherein when the at least performance-enhancing chamber is a hidden chamber, the adhesive used for filling is non-transparent.

14.- A vehicle roof or vehicle window comprising a laminated glazing (10) according to any one of the preceding claims.

15.- A method for manufacturing a laminated glazing (10) according to any of claims 1 to 13, comprising the following steps: a) placing at least one plastic bonding layer (2) on the interior surface of a first glass layer (1), b) placing a non-adhesive plastic interlayer on the surface of the at least one plastic bonding layer not in contact with the first glass layer, c) placing the interior surface of a second glass layer (4) onto the surface of the non-adhesive plastic interlayer not in contact with said at least one plastic bonding layer, d) laminating with heat and pressure the product resulting from the previous step, e) removing the non-adhesive plastic interlayer and the second glass layer (4), forming a first pre-assembly, f) arranging an active film (6) spaced from the surface of the at least one plastic bonding layer (2) of the first pre-assembly, wherein the active film (6) is spaced from said at least one plastic bonding layer (2) by first spacing means (5) such that a gap (G) is formed, g) filling the gap (G) in between the at least one plastic bonding layer (2) and the active film (6) with a curable liquid optically clear adhesive, h) curing the product resulting from the previous step, i) placing second spacing means (7) onto the at least one plastic bonding layer (2) and third spacing means (8) onto at least a portion of the active film (6), j) placing the second glass layer (4) onto the product resulting from the previous step, such that the second spacing means (7) is arranged between the at least one plastic bonding layer (2) and the interior surface of the second glass layer (4) and the third spacing means (8) is arranged between at least a portion of the active film (6) and the second glass layer (4), wherein the first (5), second (7) and third (8) spacing means are arranged to form a plurality of chambers (C), wherein the exterior surface of the second glass layer (4) is oriented towards the outside of the laminated glazing (10), k) filling the plurality of chambers (C) with at least one curable liquid optically clear adhesive, l) curing the product resulting from the previous step.

16.- The method according to claim 15, wherein the curing of steps h) and/or I) are made by UV light curing, platinum curing, moisture curing, thermal curing, catalyst curing or room temperature curing.

17. The method according to any of claims 15 to 16, wherein step f) comprises forming a second pre-assembly by arranging the first spacing means (5) on the active film (6) and curing, and wherein the second pre-assembly is placed onto the surface of the at least one plastic bonding layer (2) of the first pre-assembly.