WO2024116075A1 - Stratifié à bord scellé avec insert et procédé de production - Google Patents

Stratifié à bord scellé avec insert et procédé de production Download PDF

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Publication number
WO2024116075A1
WO2024116075A1 PCT/IB2023/061988 IB2023061988W WO2024116075A1 WO 2024116075 A1 WO2024116075 A1 WO 2024116075A1 IB 2023061988 W IB2023061988 W IB 2023061988W WO 2024116075 A1 WO2024116075 A1 WO 2024116075A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
glass
laminated glazing
glass layer
plastic interlayer
Prior art date
Application number
PCT/IB2023/061988
Other languages
English (en)
Inventor
Natalia Andrea RUEDA GUERRERO
Stefan GOSSEN
Juan Felipe CASTRO LANDINEZ
Noelia CABRERA
Mauricio SALAZAR ASTETE
Daniel ESTRADA DIAGO
Katherine TOFEÑO
Original Assignee
Agp Worldwide Operations Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Agp Worldwide Operations Gmbh filed Critical Agp Worldwide Operations Gmbh
Publication of WO2024116075A1 publication Critical patent/WO2024116075A1/fr

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Classifications

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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
    • B32B17/10036—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising two outer glass sheets
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    • B32B17/10165—Functional features of the laminated safety glass or glazing
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    • B32B17/10908—Making laminated safety glass or glazing; Apparatus therefor by introducing interlayers of synthetic resin in liquid form
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    • B32B2605/08—Cars

Definitions

  • the invention relates to the field of automotive glazing.
  • the system provides: adaptive cruise control, lane keep assist, sway warning, pre-collision braking, and throttle management.
  • the system utilizes two cameras mounted on either side of the rear-view mirror as well as several sensors mounted in other locations. To date they have delivered over one million vehicles with this technology.
  • the windshield is an integral part of this system.
  • Laminated glazing lends themselves well to many of the innovative technologies.
  • the glazing surrounds and encloses the passenger compartment and occupies a substantial portion of the cabin interior and vehicle exterior surface area. It is also possible to embed various materials and devices within the soft polymer layers of the glazing where they are protected by the hard transparent glass layers.
  • inserts We shall refer to the several types of materials, components and devices that are embedded within the laminate as inserts.
  • inserts We can classify inserts as passive or active. Heat reflecting solar control films are an example of a passive insert which requires no power. Active inserts are those that require an electrically conductive connection from the insert to the exterior of the glazing. Films on which the level of light transmission can be varied electrically are an example of active inserts.
  • laminates containing LED lights, touch sensors, heated defroster circuits, antennas and other electrical devices are also active inserts.
  • Laminates in general, are articles comprised of multiple layers of thin, relative to their length and width, material, with each thin layer having two oppositely disposed major faces, typically of uniform thickness, which are permanently bonded to one and other across at least one major face of each layer.
  • the layers of a laminate may alternately be described as sheets or plies.
  • the glass layers of a glazing may be referred to as panes.
  • Laminated safety glass is made by bonding two layers of annealed glass together using a polymer bonding layer comprised of a thin sheet of transparent thermoplastic (interlayer).
  • Safety glass is glass that conforms to all applicable industry and government regulatory safety requirements for the application.
  • Annealed glass is glass that has been slowly cooled from the bending temperature down through the glass transition range. This process relieves any stress left in the glass from the bending process. Annealed glass breaks into large shards with sharp edges. When laminated safety glass breaks, the shards of broken glass are held together, much like the pieces of a jigsaw puzzle, by the polymer layer helping to maintain the structural integrity of the glass. A vehicle with a broken windshield can still be operated. The polymer layer also helps to prevent penetration by objects striking the laminate from the exterior and in the event of a crash occupant retention is improved.
  • Tempered glass has a layer of high compression on the outside surfaces of the glass, balanced by tension on the inside of the glass which is produced by the rapid cooling of the hot softened glass. When tempered glass breaks, the tension and compression are no longer in balance and the glass breaks into small beads with dull edges. Tempered glass is much stronger than annealed laminated glass. Due to the lower cost and higher strength of tempered glass, tempered glass has been favored for all but the windshield position where tempered glass is not permitted. While laminated glass is only required for the windshield, it is being used in other positions increasingly. On some higher end vehicles, laminated glass is being used for the doors rather than tempered glass to improve safety and security.
  • a standard laminate provides improved sound dampening.
  • the use of a laminate also enables and facilitates the use of heat reflecting solar control coatings and films which cannot be used with single layer tempered glass.
  • the enhanced characteristics of a laminated window are enabled in large part by the polymer bonding layer holding the two glass layers together.
  • the polymer bonding layer has the primary function of bonding the major faces of adjacent layers to each other.
  • the material selected is typically a clear thermoplastic polymer.
  • the polymer interlayer used to laminate all safety glass windshields is index matched to the index of refraction of the glass to prevent internal reflections. While there are numerous transparent plastics, few have the required level of adhesion to glass and can survive the extremes of temperature and UV exposure for the life of the vehicle.
  • the preferred bonding layer is polyvinyl butyral (PVB).
  • PVB polyvinyl butyral
  • adhesion to glass and is optically clear once laminated.
  • Automotive interlayers are made by an extrusion process. To facilitate the handling of the polymer sheet during assembly the surfaces of the interlayer are normally embossed, as a smooth surface tends to stick to the glass trapping air and making it difficult to position the interlayer on the glass. Standard thicknesses for automotive PVB interlayer at 0.38 mm and 0.76 mm (15 and 30 mil).
  • Automotive PVB is a highly engineered and optimized material. PVB has been specially formulated for automotive use. The formulas and manufacturing methods have continually been improved over the course of several decades. Even still, all grades of PVB cannot be used for all automotive laminates. Laminates that utilize a coating on one of the surface internal to the laminate may need to use a specially formulated PVB due to the difference in adhesion between the PVB and glass versus PVB and the coating. If the adhesion is too high, the PVB will tear rather than stretch. If the adhesion is too low, the glass will not adhere to the PVB leading to spalling.
  • interlayers are not transparent. They are translucent and have an embossed surface. Heat and pressure are required to bond the interlayer to the glass and to make the interlayer transparent and optically clear.
  • the interlayer should first be processed in an autoclave to eliminate the embossing and optically convert to a transparent state. In the autoclave, the assembled layers of the laminate are subject to high pressure and temperature. The temperature is elevated into the glass transition range of the interlayer where the pressure forces the viscose thermoform plastic to flow and take on the shape of the glass layers.
  • PVB The performance of the PVB is so critical to safety that manufacturers sample and test laminated automotive glazing in production on a regular basis in order to meet regulatory requirements.
  • the interlayer is soft and pliable, it is possible to embed some of the various articles needed to implement additional functionality within the laminate.
  • an insert can be laminated if the thickness is not more than 1/3 of the total thickness of the interlayer.
  • the interlayer is soft at room temperature. During the lamination process, the interlayer is held at an elevated temperature under high pressure and will flow to accommodate the insert if the insert is thin enough.
  • the maximum insert thickness will depend upon other factors such as the other dimensions of the object, the thickness of the glass, the strength of the glass, the specific interlayer and the time, temperature, and pressure of the lamination cycle. If the object is too thick, the glass may break. Objectionable distortion can also occur. With all other factors remaining the same, thinner is always better with respect to the risk of breakage and distortion.
  • VLT variable light transmission film
  • electrochromic, photochromic, thermochromic and electric field sensitive films which can be incorporated into laminated glass. Electric field sensitive films include Suspended Particle Device (SPD) films, Liquid Crystal (LC) and Polymer Dispensed Liquid Crystal (PDLC) films.
  • VLT film electrochromic (EC) switches in response to an electrical current.
  • PNLC Polymer Network Liquid Crystal
  • Variable light transmission films, as well as other performance films are sandwiched between two sheets of interlayer due to the large area that they cover.
  • One sheet of interlayer is required for each of the two major faces of the insert so as to bond each film face to the other layers of the laminate.
  • the VLT film Due to the thickness of the VLT film in the area where the bus bars and connectors are attached, the film can be difficult to laminate even with two full thickness layers of interlayer.
  • VLT films With VLT films a thicker insert can be accommodated than would otherwise be possible due to the two sheets of interlayer required.
  • an insert With VLT films a thicker insert can be accommodated than would otherwise be possible due to the two sheets of interlayer required.
  • applying the 1/3 rule of thumb with an 0.76 mm and an 0.36 mm interlayer, we can have an insert with a thickness of up to 0.36 mm.
  • VLT films draw very little power and as a result do not require thick or wide bus bars, that maximum thickness is typically sufficient.
  • the only area where we may have a problem is where the connector that brings power into the laminate is attached to the bus bar, which may increase the thickness.
  • Wire embedded heated laminates as well as laminates with VLT films also require the addition of bus bars to distribute the electrical power needed, further increasing the thickness in the bus bar areas.
  • embedded wire heated circuit bus bars a substantial amount of current is drawn requiring thicker and wider bus bars.
  • the maximum thickness of the insert is less than that of a VLT film with two layers of interlayer. When this is the case, it is often necessary to "carve" a trough in the PVB for the bus bars.
  • Active inserts comprising LEDs, touch sensors, light fibers, sensors, and other devices due to their thickness and irregular shape can present a challenge when working with polymer interlayer sheets.
  • the lamination may be successful.
  • Other process parameters also have to be adjusted. It is advisable to heat and soften the interlayer before vacuum is applied and to ramp up pressure at a slower rate than would otherwise be used. A higher temperature may also be needed to allow the interlayer to better flow.
  • Laminates with inserts share some common disadvantages.
  • the lamination process includes the steps of assembling the layers, removing air from the assembly, and then processing the assembly at an elevated temperature and pressure in an autoclave.
  • the assembly Prior to the autoclave step, it is necessary to remove as much air as possible from the assembly.
  • There are two widely used methods to remove the air from a laminate the vacuum method, and the pinch roller method.
  • the laminate is heated so as to partially melt the interlayer causing it to adhere to the glass layers and seal the edges.
  • the assembly is heated to a temperature that is high enough to make the interlayer tacky and remove the embossing pattern on the interlayer surface but not high enough to completely melt the interlayer and make it optically transparent.
  • the pinch roller system is used for most ordinary laminates, which do not have extreme curvature or inserts.
  • the heated assembly is passed through a set of soft flexible rollers, curved to the average shape of the laminate which are used to pinch the two layers together adhering the glass layers to the tacky interlayer and forcing the air out.
  • the small amount of air remaining is forced out by the high pressure of the autoclave.
  • the vacuum method is used to evacuate the air from the laminate and adhere the glass layers to the interlayer.
  • the entire assembly is placed inside of a bag, or a channel is applied to the periphery.
  • the assembly is heated with the vacuum applied and atmospheric pressure forces the assembly together.
  • This method is used for most laminates with inserts including performance films.
  • the labor associated with the vacuum method is much higher. In general, additional workers are needed to apply and remove the channel or bag whereas the pinch roller method is largely automated. The duration of the lamination process may also need to be increased.
  • the areas of high tension may lead to the premature failure of the glass.
  • the probability of failure is a function of stress, duration, and time. If there is any stress locked in the glass, the duration goes to infinity and the probability of breakage goes to 100% although the time that it may take can be quite lengthy at low levels of stress. At any rate, the probability of breakage will be greater than zero.
  • liquid adhesive It would be advantageous to fill the gap between the layers of the laminate with a viscous, transparent, optically clear, index of refraction matched, liquid adhesive, which would fill and conform to the gap between layers and to the contours of the various inserts that may be needed.
  • the liquid also should have sufficient adhesion to the glass and other inserts and the capability to be cured after the gap has been filled.
  • the LOCA As the LOCA is a liquid, the LOCA has to be contained within the two glass layers of the laminate while the void is filled and cured. This is performed with the help of a dam. The dam is applied to the interior glass surfaces creating a gap between the two glass surfaces which is subsequently filled with a LOCA.
  • thermoset LOCAs While optically clear thermoset LOCAs have been available for many years, they have primarily been used for non-glazing applications where the gap between the laminate layers is very large and/or irregular.
  • LOCAs that are UV cured are preferred due to their short cure time.
  • LOCAs there are a limited number of LOCAs that are suitable for automotive use. Any product that is used in a vehicle should meet the very severe automotive environmental test requirements.
  • the glazing should be able to withstand extremes of temperature ranging from -40 °C to 80 °C, 100% humidity, intense UV exposure, salt exposure and many other requirements. Further, the glazing needs to last for the life of the vehicle.
  • the LOCA should also be environmentally friendly and not toxic.
  • LOCA is a thermoset resin material. It is in the form of a liquid and should be dispensed or injected into the gap it needs to fill. After injected, it needs to be cured. Curing is the process of polymerization of the resin material. The polymer chains suffer cross-linking which hardens the material. After curing, LOCA resin is completely solid. The curing or hardening process in this case is irreversible. Once cured, the LOCA will never become liquid again.
  • LOCA laminates uncounted when used to make automotive safety glass is their adhesion.
  • the adhesion to glass can be too high or too low. In either case the penetration resistance of the laminate may not be sufficient to meet regulatory requirements. It can also be difficult to fill the gaps between the two glass layers and the insert with the LOCA and remove all air. It can also be difficult to achieve uniform thickness of the LOCA.
  • LOCAs that are suitable for automotive glazing use are susceptible to degradation from exposure to water.
  • the ingress of water can cause the LOCA to lose its transparency and in extreme cases cause the bond to the glass to weaken allowing the glazing to de-laminate, requiring replacement.
  • the active inserts are also likely to be damaged by exposure to humidity and water.
  • glazing that is laminated with a LOCA also needs to have an edge seal to protect the LOCA and insert.
  • the material used to fabricate the dam may also be sensitive to water.
  • edge seal Like the LOCAs, there are a very limited number of materials that are suitable for use in automotive glazing as an edge seal.
  • the edge should provide a moisture barrier, have good adhesion to glass, the LOCA and the dam material, and last the life of the vehicle.
  • a combination of materials is used with two or more edge sealants applied increasing cost and complexity.
  • a hybrid lamination process comprising both hot and cold lamination is used to enable the lamination of inserts, including heat, pressure or vacuum sensitive inserts that would not otherwise be possible to fabricate, with the use of traditional lamination materials and processes.
  • a sheet of interlayer is laminated to a bent glass layer.
  • the interlayer provides UV protection and penetration resistance.
  • the cold portion then follows.
  • a first dam is applied to the interlayer.
  • the insert is placed over and bonded to the first dam.
  • the volume enclosed is then filled with LOCA forming a first assembly.
  • a second dam is applied to a second glass layer forming a second assembly and this second assembly is joined to the first assembly.
  • the gap between the second glass, dam and insert is filled again with LOCA.
  • Figure IB shows a cross section of typical laminate with coating on surface two and a performance film.
  • Figure 2 shows an exploded isometric view of laminated roof according to an embodiment of the invention.
  • Figure 3 shows a top view of the laminated roof in Figure 2.
  • Figure 4A shows a cross section of pre-assembly with separator and both glass layers according to an embodiment of the invention.
  • Figure 4B shows an exploded cross section of pre-assembly with separator and both glass layers.
  • Figure 4C shows an exploded cross section of first and second pre-assemblies with the separator.
  • Figure 5A shows a Cross section of the first pre-assembly with first dam applied.
  • Figure 5B shows a Cross section of 5A with insert.
  • Figure 5C shows a Cross section of 5B with the first LOCA fill.
  • Figure 6A shows a Cross section of 5C with second dam and second glass layer.
  • Figure 6B shows a Cross section of 6A with second LOCA fill.
  • Figure 7A shows a Cross section of 6B with edge seal.
  • Figure 7B shows a Cross section of 8C with edge seal.
  • Figure 8A shows a Cross section of the first pre-assembly with the first dam applied.
  • Figure 8B shows a Cross section of 8A with insert.
  • Figure 8C shows a Cross section of 8B with the first LOCA fill.
  • Figure 9A shows a Cross section of 8C with second dam and second glass layer.
  • Figure 9B shows a Cross section of 9A with second LOCA fill.
  • Figure 10A shows a cross section of a glazing of this invention similar to Figure 7A, further comprising a second plastic interlayer.
  • Figure 10B shows a cross section of a glazing of this invention similar to Figure 7B, further comprising a second plastic interlayer.
  • Typical automotive laminated glazing cross-sections are illustrated in Figures 1A and IB.
  • the laminate is comprised of two layers of glass 2, the first glass layer, 201 and the second glass layer, 202 that are permanently bonded together by a plastic interlayer 4.
  • the glass surface of the first glass layer 201 which faces the exterior of the laminate is referred to as surface one, 101, or the number one surface.
  • the opposite face of the first glass layer 201 is surface two, 102, or the number two surface.
  • Surface two faces the interior of the glazing.
  • the surface of the second glass layer 202 that faces the exterior of the laminate is referred to as surface four, 104, or the number four surface.
  • the opposite face of the second glass 202 which faces the interior of the glazing is surface three, 103, or the number three surface. Surfaces two, 102, and three, 103 are bonded together by the plastic interlayer 4. An obscuration 6 may also be applied to the glass. Obscurations are commonly comprised of black enamel frit printed on either the number two, 102, or number four surface, 104, or on both.
  • the laminate may have a coating 18 on one or more of the surfaces.
  • the laminate may also comprise a film 12 laminated between at least two plastic interlayers 4 ( Figure IB).
  • glass can be applied to many inorganic materials, including many that are not transparent. For this document we will only be referring to transparent glass. 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.
  • Glass is formed by mixing various substances together and then heating to a temperature where they melt and fully dissolve in each other, forming a miscible homogeneous fluid.
  • a glazing is an article comprised of at least one layer of a transparent material which serves to provide for the transmission of light and/or to provide for viewing of the side opposite the viewer and which is mounted in an opening in a building, vehicle, wall or roof or other framing member or enclosure.
  • a laminated glazing can be curved or flat.
  • the individual layers can be curved separately or simultaneously bent by means of hot bending, such as gravity bending, pressbending or a combination of.
  • hot bending such as gravity bending, pressbending or a combination of.
  • one of the glass layers could be cold bent, meaning that it conforms to the shape of the other glass layer only during lamination. In that case, usually there are surface tensions created onto the glass that was cold-bent. In most cases the cold-bent glass layer should be strengthened so the surface tensions created during and after the cold-bending could be accounted for.
  • the types of glass that may be used include but are not limited to the common soda-lime variety typical of automotive glazing as well as aluminosilicate, lithium aluminosilicate, borosilicate, glass ceramics, and the various other inorganic solid amorphous compositions which undergo a glass transition and are classified as glass included those that are not transparent.
  • the glass layers may be comprised of heat absorbing glass compositions as well as infrared reflecting and other types of coatings.
  • thermoset LOCAs are available. As the items being laminated are transparent, the most convenient LOCA type for automotive glazing are those that are cured by means of exposure to light. LOCAs are available that are sensitive to and cured at various light frequencies with UV being the most common. However, this is not to be taken as a limitation. LOCAs that are cured by other means may be used and are considered equivalent such as UV light curing, platinum curing, moisture curing, thermal curing, catalyst curing, room temperature curing, or a combination thereof.
  • the LOCA composition of this invention could comprise any of the following: are selected from the group of epoxy-based adhesive, acrylic-based adhesive, silicone-based adhesive, urethane- based adhesive, and a combination thereof.
  • the laminated glazing of the present disclosure comprises a first glass layer having an exterior surface oriented towards the outside of the laminated glazing, and an interior surface oriented towards the inside of the laminated glazing; a first plastic interlayer having a length Lj, a width w; and edges, being arranged in between the active film and the interior surface of the first glass layer; an active film, having a length Lf, a width Wf, and edges, wherein the length Lf is smaller than the length Lj, and the width Wf is smaller than the width wi; a first dam located or arranged between said first plastic interlayer and the active film, the first dam being arranged to form a first gap between the first plastic interlayer and the active film; a first curable liquid optically clear adhesive that fills the first gap; 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 being disposed such as to form a second gap between the second glass layer interior surface and the active film surface that does not face the first plastic
  • the edges of the active insert are normally hidden from view from the interior or exterior of the vehicle by an obscuration typically applied to surface two, 102, of the first glass layer, 201, and surface four, 104, of the second glass layer, 202. Therefore at least one obscuration layer may be disposed onto the perimeter of the interior surface of the first glass layer and/or disposed onto the perimeter of either the interior or exterior surfaces of the second glass layer and having a width Wo such that w 0 is greater than w e . Additionally, the one or more obscuration layers may be comprised of one of the following: an opaque plastic layer, and a black enamel frit or an organic ink printed onto either or both of the glass layers. Preferably obscurations may have a light transmission of below 5 %.
  • the width of the obscuration is sufficient to hide at least the edge seal, and preferably also the dam and the portions of the active insert that are not intended to be visible. This includes any electrical connection points.
  • the edge seal is applied around substantially the entire perimeter of the glazing.
  • a hybrid lamination process is used.
  • a combination of both hot and cold lamination methods is used. This enables the lamination of inserts, including heat, pressure or vacuum sensitive inserts that would not otherwise be practical or even possible to fabricate with traditional lamination materials and processes alone.
  • a laminate fabricated with just a LOCA bonding together with the glass layers is not likely to be able to pass regulatory requirements for penetration resistance or be able to provide the level of ultraviolet (UV) light protection needed.
  • the hot lamination process is used to bond an interlayer to a glass layer forming a pre-assembly.
  • the first plastic interlayer is in contact with the first glass layer.
  • This pre-assembly provides the penetration resistance and UV protection needed. UV protection can be guaranteed by either a UV performance interlayer or by using a first glass layer having UV protection.
  • the UV protection required by the variable light transmission inserts is a light transmission of less than 20%, and preferably less than 5% in the wavelength range of 280 nm to 410 nm.
  • the pre-assembly is then laminated to the insert using a cold lamination process which allows for the use of inserts that are not practical or possible to laminate by hot lamination methods alone.
  • inserts will be damaged or destroyed by the heat and pressure of the autoclave.
  • the inserts may also be damaged or destroyed by the vacuum that is typically needed to remove the air from the layers when an insert is used between two plastic interlayers.
  • Standard PVB contains UV blockers.
  • Specially formulated PVB is also available with enhanced UV protection that blocks substantially all UV light spectrum as well as light in the near UV. This UV enhanced PVB was developed specificallyfor use with certain types of VLT films.
  • LOCAs do not typically contain UV blockers, especially those that cure and cross-link by means of UV exposure.
  • the interlayer 4 is laminated to surface two, 102, of the first glass layer, 201. This is the hot lamination portion of the method and is very similar to the method used for standard laminates. The process is illustrated in Figures 4A and 4B.
  • the plastic interlayer 4 is comprised of any of the following polyvinyl butyral (PVB), ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), polyolefin elastomers (PoE), or a combination thereof.
  • the plastic interlayer 4 is placed between the two bent glass layers 201, 202 as is done with a typical laminated glazing. Alternately, rather than using the second glass layer 202, a reusable mold may be used in its place.
  • a separator such as a non-adhesive plastic interlayer 30 is placed between the plastic interlayer 4 and surface three, 103, of the second glass layer, 202.
  • the separator 30 is made of a material that will not stick to the glass or reusable mold and that the plastic interlayer 4 may be desired not to stick too.
  • This first pre-assembly of first glass layer, separator layer (optional), and first plastic interlayer (Figure 4A) is processed through a typical autoclave lamination cycle with heat and pressure.
  • the method for making the first pre-assembly is as follows: providing a first glass layer having an exterior surface oriented towards the outside of the laminated glazing, and an interior surface oriented towards the inside of the laminated glazing; placing a first plastic interlayer on the interior surface of the first glass layer; placing a separator layer on the surface of the first plastic interlayer, which is not in contact with the first glass layer; providing a reusable mold or a second glass layer having an exterior surface oriented towards the outside of the laminated glazing, and an interior surface oriented towards the inside of the laminated glazing; placing a mold or the interior surface of the second glass layer onto the surface of the separator layer not in contact with said first plastic interlayer, and laminating with heat and pressure;
  • first glass layer 201 with the first plastic interlayer bonded to it, the separator, and the second glass layer 202 or mold are separated ( Figure 4B).
  • the intent is to allow for lamination of the first glass layer with the first plastic interlayer.
  • the assembly of the outer glass 201 and the first glass layer interlayer, with optionally the separator 30, forms the first pre-assembly 32.
  • suitable separator layers are PET, COP, PC, PS, PE, PMMA, and the combination of thereof.
  • the separator 30 may be discarded or reused depending upon its construction.
  • the separator 30 may also be left in the first pre-assembly.
  • the first pre-assembly is comprised of a separator layer arranged in between the first plastic interlayer and the active film such that the first dam is arranged in between said separator layer and the active film forming the first a gap.
  • the first dam is made of a thermoplastic material.
  • the glass layers 201 and 202 could be curved or flat.
  • the second glass layer 202 could also have a plastic interlayer 4, referred to a second plastic interlayer bonded to it and forming a second pre-assembly. This is illustrated by Figure 4C.
  • the method is further comprised by the following: providing a second plastic interlayer; providing and placing the second plastic interlayer on the interior surface of the second glass layer; placing the second glass layer with the second plastic interlayer together with the first pre-assembly such that the first separator layer is disposed in between the first and the second plastic interlayer, and laminating with heat and pressure; separating the first pre-assembly, which is comprised of the first glass layer with the first plastic interlayer, from the second pre-assembly, which comprises the second glass layer with the second plastic interlayer; and optionally removing the first separator layer from the first pre-assembly.
  • the first pre-assembly 32 is then used as the base for the cold lamination steps.
  • the cold lamination method follows the steps below: arranging an active film onto the surface of either the separator layer or first plastic interlayer of the first pre-assembly, wherein the active film is spaced from said separator layer or first plastic interlayer by first dam such that a first gap is formed; filling the first gap in between either the separator layer or the first plastic interlayer, and the active film with a first curable liquid optically clear adhesive; placing a frame-like edge seal made of a thermoplastic material on the perimeter of either the first plastic interlayer, isolator layer, or the second glass layer; joining the second glass layer, the edge seal, and the first pre-assembly such as to form a second gap in between the second glass layer and the active film, and heating said edge seal to a temperature that promotes bonding of the edge seal to the adjacent layers; filling the second gap in between the active film and the second glass layer with a second curable liquid optically
  • Figure 5A illustrates applying of the first dam 26, and bond the insert 24 to the first dam 26 is illustrated by Figure 5B.
  • the volume enclosed between the insert 24, the first dam 26, and the pre-assembly 32 is filled the volume with a first LOCA 20, forming a first assembly, as shown in Figure 5C.
  • a second dam 28 is applied to a second glass layer 202 and the second glass layer is joined to the first assembly such that the second dam 28 is in between the second glass 202 and the pre-assembly 32 as shown in Figure 6A.
  • the volume enclosed between the second glass, the second dam 28 and the prelaminated 32 is filled with a second LOCA, as shown in Figure 6B.
  • the first and second LOCAs are cured by any adequate means.
  • an edge seal 16 is dispensed and cured in the periphery of the glazing arranged such as to protect the dams, the LOCAs and the insert illustrated in Figure 7A.
  • the temperature necessary to promote bonding of the edge seal to the adjacent layers can vary from at least 60 °C, more preferably at least 80 °C.
  • a second dam is placed in between the second glass layer interior surface and the active film surface that does not face the first plastic interlayer, wherein the second dam contains and seals the second curable optically clear adhesive layer.
  • This steps are illustrated in Figures 9A and 9B leading to the final product 7B.
  • the isometric exploded view of this embodiment is illustrated in Figure 2.
  • Figure 3 is a top view of the laminated roof of Figure 2.
  • the second dam is made of a thermoplastic material.
  • the laminated glazing of the invention may further comprise a second plastic interlayer disposed onto the second glass layer, similarly illustrated by Figures 10A and 10B, which are equivalent to Figures 7A and 7B, however comprising the second plastic interlayer.
  • the laminated glazing of the invention may further comprise of a low emissivity and/or anti-reflective coating applied to the exterior surface of the second glass layer.
  • Example one is the hybrid laminated roof with edge seal aspects of which are shown in Figures 2, 3, 4A, 4B, 5A, 5B, 5C, 6A, 6B and 7A.
  • the inner 202 glass layer is comprised of 2.3 mm clear soda-lime glass.
  • the outer 201 glass layer is 2.6 mm dark solar green soda-lime glass.
  • the overall dimension of the roof is 800 mm by 1200 mm.
  • a black frit obscuration 6 is screen printed on surface two, 102.
  • Surface four, 104 of the inner glass layer 202 is printed with a pattern that has voids in the print totaling 10% of the printed area to allow for the UV LOCA to cure.
  • the width of the obscuration is 100 mm.
  • An MSVD solar control coating is applied to surface two, 102 of the outer glass 201 layer.
  • An MSVD low-e coating is applied to surface four, 104 of the inner glass layer.
  • the two glass layers are bent and allowed to cool.
  • the outer glass layer 201 and a sheet of 1 mm thick enhanced UV block PVB are assembled and proceed as previously described to form the prelaminated 32.
  • the first pre-assembly 32 is positioned with surface two 102 facing up.
  • a first dam 26 is applied to the interlayer 4 ( Figure 5A).
  • a number of materials and methods may be used to form the dam.
  • a semi-viscous fluid may be extruded to form the first dam 26 and the second dam 28.
  • the dam may comprise a solid that is bonded to the interlayer 4.
  • the material used is compatible with the LOCA, interlayer and the insert.
  • the size of the insert is kept at the minimum needed to cover the desired portion of the glazing while allowing for good aesthetics. This is generally just outboard of the inboard edge of the black obscuration. Some additional material is needed to account for the tolerance stack. Some also need to be allocated so as to allow the insert to be bonded to the dam which is required to contain the LOCA during the filling step.
  • the insert may at least partially overlap substantially the periphery of the dam and be bonded to it. In a preferred embodiment the insert may at least partially overlap substantially the entire periphery of the dam and be bonded. Some voids may be intentionally made in the dam to create ports for the injection of LOCA and evacuation of air as well as for electrical connections.
  • the placement of the dam will depend upon the cut size of the insert.
  • the dam is placed sufficiently inboard of the edge of glass to provide space for the edge seal required.
  • the edge seal width is typically at least 1 mm wide, preferably 3 mm wide. More preferably the edge seal is above 5 mm. Generally, this is in the 6 mm - 12 mm range. It could also be advantageous to have an edge seal of at least 10 mm wide. The edge seal could also be as wide as 500 mm.
  • the width of the dam will depend upon the type of material used.
  • the height (thickness) of the edge seal is at least 0.30 mm, preferably at least 0.70 mm to account for the thicknesses of the active film and the liquid optically clear adhesive layers.
  • the height or thickness is no more than 2.30 mm, and preferably no more than 6.00 mm.
  • the thickness of the dam will generally be at least that of a standard automotive interlayer, such as 0.70 mm but can be greater or less.
  • the thickness of the dam will determine the thickness of the LOCA layer.
  • the first dam of this example has a width of 12 mm and a thickness of 1 mm.
  • a thermoform plastic is extruded onto the PVB interlayer side of the pre-assembly 32. The elevated temperature of the extruded material partially melts the PVB and bonds to it.
  • the active insert 24 is a sheet of SPD VLT with a thickness of 250 pm, as shown in the figures.
  • the insert is cut to 25 mm larger than the inboard edge of the obscuration and formed to the curvature of the glass surface. Bus bars and connectors are applied.
  • an installation tool is used to support and hold the insert and to maintain its shape. This is needed to maintain a uniform LOCA thickness.
  • the insert is affixed to a full surface positive tool and held in place by means of a vacuum.
  • the insert 24 is bonded by means of an adhesive (not shown) to the first dam 26 enclosing a volume bounded by the inboard side of the first dam 26, the inboard surface of the pre-assembly 32 and the dam 26 side surface of the insert 24 ( Figure 5B).
  • This enclosed volume is filled with a LOCA creating the first LOCA 20 layer (Figure 5C).
  • the first LOCA layer 20 may be cured at this point or later after the other second LOCA layer 22 is added.
  • the second dam 28 is applied to the second glass layer 202 and it all is joined and bonded to the first assembly. (Figure 6A).
  • the second dam is 12 mm wide and 2.5 mm thick.
  • the second dam has an outboard edge that is 12 mm inboard from the edge of the second glass layer 202 so as to allow space for the edge seal 16.
  • the LOCA layers are allowed to cure.
  • edge seal 16 is sealed by an edge seal 16.
  • ordinary automotive interlayers which already meet the criteria for glass adhesion and durability, are compatible with most dam materials and LOCAs and also provide an adequate moisture resistant edge seal.
  • PVB, EVA, TPU, PoE, ionomer, and acrylic are examples of suitable materials chosen for the edge seal.
  • PVB is used to fill the gap between the glass layers extending from the dam to the edge of glass.
  • the PVB is heated into its glass transition range and extruded. The cross section of the resulting laminate is shown in Figure 7A.
  • Example 2 Example 2
  • Example two a hybrid laminated roof with edge seal, is similar to example one in most respects.
  • the pre-assembly is formed in the same hot lamination method as in the example one.
  • the cold lamination steps of the method are shown in Figures 8A, 8B, 8C, 9A, 9B and 7B.
  • the first dam 26 of this example has a width of 12 mm and a thickness of 1 mm.
  • the outboard edge of the dam is located 12 mm inboard of the edge of glass.
  • thermoform plastic is extruded onto the PVB interlayer side of the pre-assembly 32 ( Figure 8A).
  • the elevated temperature of the extruded material partially melts the PVB and bonds to it.
  • the active insert 24 is a sheet of SPD VLT with a thickness of 250 pm, as shown in the figures.
  • the insert is cut to 20 mm smaller than the outboard edge of the glass and formed to the curvature of the glass surface. Bus bars and connectors are applied. This is done to obscure forming defects in the insert that tend to occur near the edges. With a 100 mm wide black obscuration 6, nominally, 80 mm of the insert will be hidden. Figures are exaggerated and do not follow the exact measurements with the intend to only illustrate the main aspects of the invention.
  • a tool is used to hold the insert and to maintain its shape. This is needed to maintain a uniform LOCA thickness.
  • the insert is affixed to a full surface positive tool and held in place by means of a vacuum.
  • the insert 24 is bonded by means of an adhesive (not shown in the figure) to the first dam 26 enclosing a volume bounded by the inboard side of the first dam 24, the inboard surface of the pre-assembly 32 and the dam 26 side surface of the insert ( Figure 8B).
  • This enclosed volume is filled with a LOCA creating the first LOCA 20 layer (Figure 8C).
  • the first LOCA layer 20 may be cured at this point or later after the other second LOCA layer 22 is added.
  • the second dam 28 is applied to the second glass layer 202 and it is joined to the first assembly ( Figure 9A).
  • the second dam is 12 mm wide and 2.5 mm thick.
  • the dam has an outboard edge that is 12 mm inboard from the edge of glass so as to allow space for the edge seal 16.
  • the second dam 28 is located directly over the first dam 26.
  • the LOCA layers are allowed to cure.
  • Figure 7B illustrates a glazing of this invention further comprising a second plastic interlayer disposed onto the second glass layer.
  • Embodiment one is the laminated glazing of example one wherein the active insert is any of the following: a LC VLT film, a PDLC VLT film, PNLC VLT film or an electrochromic VLT film.
  • Embodiment two is the laminated glazing of example two wherein the active insert is any of the following: a LC VLT film, a PDLC VLT film, PNLC VLT film, or an electrochromic VLT film.
  • Embodiment three is the laminated glazing of example one wherein the active insert comprises an LED lighting circuit adhered to transparent PET.
  • Embodiment four is the laminated glazing of example two wherein the active insert comprises an LED lighting circuit adhered to transparent PET, and a touch sensor .
  • Embodiment five is the laminated glazing of examples one or two wherein instead of an active insert, the glazing comprises an inactive insert such as a holographic film or projection film.
  • Embodiment six is the laminated glazing of examples one or two wherein instead of PVB, the edge seal 16 is made of one of the following ethylene vinyl acetate, thermoplastic polyurethane, polyolefin elastomer, ionomer, or acrylic.

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  • Joining Of Glass To Other Materials (AREA)

Abstract

La complexité du vitrage automobile moderne augmente à mesure que l'industrie se tourne vers des véhicules totalement autonomes et comme les consommateurs demandent des niveaux accrus de confort, de commodité et de sécurité. Les stratifiés comportent souvent des composants insérés à l'intérieur du stratifié. La fabrication desdites pièces peut être difficile. Des inserts peuvent conduire à une rupture, à une distorsion et à un délaminage. De plus, certains des inserts actuellement utilisés et souhaités ne sont pas compatibles avec le vide, la chaleur et la pression du processus et certains doivent également être protégés contre les UV et l'infiltration d'eau. Le procédé innovant de stratification hybride et d'étanchéité de bord de l'invention est compatible avec des inserts qui ne seraient pas possibles ou pratiques à stratifier avec le processus de stratification automobile classique. Un pré-ensemble comprenant une couche de verre et une couche intermédiaire est d'abord formé, puis l'insert est stratifié au moyen d'un adhésif optiquement transparent liquide et le bord est scellé avec un matériau thermoplastique.
PCT/IB2023/061988 2022-11-28 2023-11-28 Stratifié à bord scellé avec insert et procédé de production WO2024116075A1 (fr)

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US63/385,170 2022-11-28

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20210138767A1 (en) * 2018-06-29 2021-05-13 Agp America S.A. Laminated glazing with a switchable liquid crystal layer
WO2024003345A1 (fr) * 2022-06-30 2024-01-04 Agp Worldwide Operations Gmbh Vitrage feuilleté à chambres indépendantes

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20210138767A1 (en) * 2018-06-29 2021-05-13 Agp America S.A. Laminated glazing with a switchable liquid crystal layer
WO2024003345A1 (fr) * 2022-06-30 2024-01-04 Agp Worldwide Operations Gmbh Vitrage feuilleté à chambres indépendantes

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