CN115551706A - 带有功能膜和集流器的复合片材 - Google Patents

带有功能膜和集流器的复合片材 Download PDF

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Publication number
CN115551706A
CN115551706A CN202280002252.0A CN202280002252A CN115551706A CN 115551706 A CN115551706 A CN 115551706A CN 202280002252 A CN202280002252 A CN 202280002252A CN 115551706 A CN115551706 A CN 115551706A
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CN
China
Prior art keywords
sheet
film
composite sheet
composite
current collector
Prior art date
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Pending
Application number
CN202280002252.0A
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English (en)
Inventor
A·帕尔曼捷
U·范德穆伦
N·廷斯
S·布鲁尔
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saint Gobain Glass France SAS
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Saint Gobain Glass France SAS
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Publication date
Application filed by Saint Gobain Glass France SAS filed Critical Saint Gobain Glass France SAS
Publication of CN115551706A publication Critical patent/CN115551706A/zh
Pending legal-status Critical Current

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  • Optics & Photonics (AREA)
  • Chemical & Material Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Joining Of Glass To Other Materials (AREA)
  • Laminated Bodies (AREA)

Abstract

一种带有功能膜(4)的复合片材(1)，至少包括复合片材(1)的环绕的棱边(K)、功能膜(4)的环绕的棱边(U)、至少一个集流器(5)、带有外侧表面(I)和内部空间侧表面(II)的外片材(2)、带有外侧表面(III)和内部空间侧表面(IV)的内片材(6)以及连接外片材(2)的内部空间侧表面(II)与内片材(6)的外侧表面(III)的热塑性中间层(3)，其中，‑功能膜(4)被嵌入热塑性中间层(3)中，‑功能膜(4)的环绕的棱边(U)相对复合片材(1)的环绕的棱边(K)在复合片材(1)的面中心方向上缩进，‑至少一个集流器(5)布置在外片材(2)的内侧表面(II)与内片材(6)的外侧表面(III)之间且在复合片材(1)的边缘区域(R)中在复合片材(1)的环绕的棱边(K)与功能膜(4)的环绕的棱边(U)之间伸延，且沿着至少一个集流器(5)在集流器(5)与功能膜(4)的环绕的棱边(U)之间的间距x为5mm与50mm之间。

Description

带有功能膜和集流器的复合片材
技术领域
本发明涉及一种包括功能膜(Funktionsfolie)和至少一个集流器(Sammelleiter)的复合片材(Verbundscheibe)以及一种用于制造这样的复合片材的方法。
背景技术
现代汽车玻璃越来越多地配备附加功能，例如可加热层、带有可电气切换的光学特性的功能元件和显示器。在此这些元件中的多个常常要被集成在一个玻璃内。
尤其地，挡风玻璃常常配备有所谓的抬头显示器(HUD)。利用典型地在仪表板区域中的投影仪，图像被投影到挡风玻璃上、在该处被反射且由驾驶员作为虚拟图像(由该驾驶员来看)在挡风玻璃之后被感知。如此，重要的信息可被投影到驾驶员的视野中，例如当前的行驶速度、导航或警告提示，驾驶员可感知这些信息而无须将其视线由车道移开。如此，抬头显示器可显著地有助于提高交通安全性。
DE 10 2014 220 189 A1公开了一种HUD投影组件，其以p偏振辐射来运行，以便于产生HUD图像。因为入射角典型地接近布鲁斯特角且p偏振辐射因此仅以较小程度被玻璃表面反射，所以挡风玻璃具有反射结构，其可反射在驾驶员的方向上的p偏振辐射。作为反射结构建议带有5nm至9nm的厚度(例如由银或铝构成的)单个金属层，其被涂覆在内片材的背对乘用车内部空间的外侧上。
在US 2004/0135742 A1中同样公开了一种HUD投影组件，其以p偏振辐射来运行，以便于产生HUD图像，且具有可在驾驶员的方向上反射p偏振辐射的反射结构。作为反射结构建议在US 5,882,774 A中所公开的多层式的聚合物层。
DE 698 20 012 T2 公开了一种用于对包括带有红外反射涂层的聚合物中间层的复合片材进行层压的方法，其中，携带红外反射涂层的聚合物中间层的层部分在复合片材的边缘区域中被去除。由此避免涂层的从片材棱边出发的腐蚀。
不仅抬头显示器而且其它的显示器应用或带有可电气切换的光学特性的功能元件常常以功能膜形式被使用。这具有如下优点，即，功能膜在对复合片材进行层压时可被容易地引入到层堆叠中且可独立于复合片材的制造被预制。在此，功能膜一般而言基于一种或多种聚合物载体膜，在其上或在其之间涂覆有功能层。这些聚合物载体膜在层压时经由热塑性复合膜被连结到复合片材的片材处。在此须注意如下，即，发生层堆叠的完全脱气且处在载体膜与复合膜之间的气穴(Lufteinschluss)也被完全去除。在此，剩余的气穴导致产品缺陷。如果除了待集成的功能膜之外安装有需要集流器以便电气接触的另外元件，则完全排气进一步变得困难。额外于所描述的问题，须越来越多地注意在集流器附近的气穴。
发明内容
因此存在对不具有现有技术的这些缺点的包括功能膜和集流器的复合片材的需求。本发明的目的在于提供一种这样的经改善的复合片材和一种用于制造所述复合片材的方法。
根据本发明，本发明的目的通过一种根据权利要求1的复合片材来实现。优选的实施方案由从属权利要求得悉。
根据本发明的复合片材包括外片材和内片材。外片材具有外侧表面I和内部空间侧表面II，而内片材具备外侧表面III和内部空间侧表面IV。外片材的内部空间侧表面II与内片材的外侧表面III经由热塑性中间层相连接。在复合片材的热塑性中间层中嵌入有功能膜。复合片材包括环绕的棱边。功能膜同样包括环绕的棱边，其中，功能膜的环绕的棱边相对复合片材的环绕的棱边在复合片材的面中心的方向上缩进。在此，功能膜嵌入在热塑性中间层中。此外，根据本发明的复合片材包括至少一个集流器。集流器在外片材的内侧表面II与内片材的外侧表面III之间被集成在复合片材中。在此，集流器在复合片材的边缘区域中在复合片材的环绕的棱边与功能膜的环绕的棱边之间伸延。根据本发明，至少一个集流器相对功能膜的环绕的棱边的间距处在5mm与50mm之间(沿着集流器测量)。在此相应地考虑在集流器与功能膜的环绕的棱边之间的最短间距。
根据本发明的复合片材使得功能膜与在复合片材的边缘区域中靠近功能膜布置的集流器的组合成为可能，而不出现复合片材的气穴和与此伴随的缺陷。发明人已经发现，对于复合片材的良好层压而言在功能膜与集流器之间的5mm至50mm的根据本发明的间距是重要的。如果间距太小，则处在功能膜的环绕的棱边与集流器之间的空气没有足够的可能性逸出。如果间距过大，则在功能膜的环绕的棱边与集流器之间的间隙不可均匀地被热塑性复合膜的在层压过程中熔融的材料填充并且同样形成缺陷处。在根据本发明的范围中，与之相反可实现无缺陷的排气。
优选地，至少一个集流器相对功能膜的环绕的棱边之间的间距为10mm至30mm、特别优选地为15mm至25mm(沿着集流器测量作为相应最短的间距)。在这些范围内可发现特别均匀的层压。
复合片材设置用于在窗口开口、尤其车辆的窗口开口中将内部空间与外部环境分开。在本发明的意义中，用内片材表示复合片材的面对内部空间(尤其车辆内部空间)的片材。用外片材表示面对外部环境的片材。复合片材优选是车辆挡风玻璃(特别是机动车的挡风玻璃、例如乘用车或载重车辆)。复合片材然而也可以是车辆的侧窗片材或车顶片材。
复合片材具有上棱边和下棱边以及在其间伸延的两个侧棱边。用上棱边表示设置用于在安装位置中向上指向的这样的棱边。用下棱边表示设置用于在安装位置中向下指向的这样的棱边。上棱边常常也被称作车顶棱边且下棱边被称作发动机棱边。
外片材和内片材相应具有外侧表面和内部空间侧表面和在其间伸延的、环绕的侧棱边。在本发明的意义中，用外侧表面表示设置用于在安装位置中面对外部环境的这样的主面。在本发明的意义中，用内部空间侧表面表示设置用于在安装位置中面对内部空间的这样的主面。外片材的内部空间侧表面和内片材的外侧表面彼此面对且通过热塑性中间层彼此相连接。
作为功能膜可使用各种各样的对于专业人士而言已知的单层或多层膜。本发明尤其适用于将功能膜与本身对玻璃显示较差粘附性的载体膜材料集成。由于对玻璃的粘附性较小，这样的载体膜被嵌入在热塑性复合膜之间，其中，这样的层堆的无气泡排气设计困难，即使在复合片材的边缘区域中没有集流器。优选地，功能膜包括至少一种基于聚对苯二甲酸乙二醇酯(PET)、聚乙烯(PE)、聚甲基丙烯酸甲酯(PMMA)、三乙酰纤维素(TAC)和/或聚碳酸酯和/或它们的共聚物或混合物的载体膜，特别优选基于聚对苯二甲酸乙二醇酯(PET)的载体膜。这些材料被使用作为市场上可获得的功能膜的载体膜材料，并显示出所描述的排气问题。在边缘区域存在集流器的情况下，排气进一步变得困难。本发明在此提供了一种补救措施。
在汽车领域中所应用的已知的功能膜例如是HUD膜、显示膜以及带有可电气切换的光学特性的功能膜。带有可电气切换的光学特性的功能膜例如包括PDLC膜、SPD膜、电致变色膜或电致发光膜。这些带有可电气切换的光学特性的功能膜一般而言设计成包括一个或多个载体膜以及布置在其上或其间的有源层的多层膜。作为载体膜材料一般而言使用PET。有源层在施加电压时改变其光学特性。
在一种可能的设计方案中，功能膜是PDLC膜(polymer dispersed liquid crystal，即聚合物分散液晶)。PDLC功能膜的有源层包含液晶，其被嵌入到聚合物基质中。有源层布置在两个载体膜之间，其中，面电极处在载体膜的面对有源层的表面上。如果电压不被施加到面电极处，则液晶无序地定向，这导致穿过有源层的光线的强烈散射。如果电压被施加到面电极处，则液晶沿共同的方向定向且光线通过有源层的透射率被提高。这样的PDLC功能膜例如由DE 102008026339 A1已知。
在另外的可能的设计方案中，功能膜是SPD、电致变色或电致发光功能膜。
SPD膜(suspended particle device，即悬浮颗粒装置)包含包括悬浮颗粒的有源层，其中，光线通过有源层的吸收可借助于将电压施加到面电极处而被改变。吸收变化基于在施加电压时棒状颗粒在电场中的定向。SPD功能膜例如由EP 0876608 B1和WO2011033313 A1已知。
在电致变色功能膜中，功能膜的有源层是电化学有源层。可见光的传输取决于离子到有源层中的嵌入度，其中，离子例如通过在有源层与面电极之间的离子存储层来提供。该传输可能被施加到面电极处的、引起离子迁移的电压影响。合适的功能层例如至少包含氧化钨或氧化钒。电致变色功能元件例如由WO 2012007334 A1、US 20120026573 A1、WO2010147494 A1和EP 1862849 A1已知。
在电致发光功能膜的情形中，有源层包含电致发光材料、尤其有机电致发光材料，其发光通过电压的施加而被激发。电致发光功能膜例如由US 2004227462 A1和WO2010112789 A2已知。电致发光功能膜可被用作简单的光源，或可作为带有任意图示的显示器被显示。
另外的在本发明的范围中优选的功能膜是包括漫反射层或入射光线漫反射的表面的显示膜。在此，漫反射在概念上被理解为非定向的反射。在漫反射层处，例如示出了投影仪的从车辆内部朝向车辆玻璃的内片材指向的图像，其中，显示膜在层压片材的平面中显示真实的图像。在此，真实图像区别于虚拟图像，其中，虚拟图像处在不同于投影平面的平面中，而真实图像显示在投影平面中。
显示膜例如包含带有漫反射涂层的漫反射内部空间侧表面。漫反射涂层优选包含纳米颗粒或微粒(例如二氧化硅颗粒、聚合物颗粒或液晶)。对此备选地也可使用金属或金属氧化物颗粒。特别地，所提及的纳米颗粒或微粒具有球形和/或是透明或透光的。特别地，特别是具有包含二氧化钛颗粒(TiOx颗粒)或银颗粒的漫反射涂层的显示膜已被证明是有利的。同样，具有有机漫反射涂层(含胆甾型液晶)的显示膜非常适合确保良好的图像质量。在特别优选的实施形式中，显示膜包括以矩阵取向的胆甾型液晶。在WO 2017/204103 A1中描述了显示膜的一个可能示例，该膜包括被折射率匹配层覆盖的随机分散的胆甾型液晶液滴。胆甾型液晶液滴基本上呈半球形，其半径取决于薄膜与液滴之间的接触角。显示膜的波长选择性同样可行，如例如在WO 2016/175183 A1中所描述的那样。
当显示膜的一个表面包括随机的纳米结构或微结构时，则优选地显示膜的另一个表面是光滑的。
在另一优选的实施形式中，显示膜包括结构化的塑料膜，其中，该塑料膜包括多个结构化表面且显示膜的特性经由相邻结构化层之间的接触面的斜度来确定。在WO 2012/104547 A1中描述了用于显示膜的层的构造的示例性的实施形式和方法。与基于颗粒的显示膜相比，在结构化的显示膜中常常须实现更少的混浊度和更好的亮度因数(也被称作“屏幕增益”)。
优选地，显示膜作为载体材料包括含有聚乙烯(PE)、聚对苯二甲酸乙二醇酯(PET)、聚甲基丙烯酸甲酯(PMMA)、三乙酰纤维素(TAC)和/或聚碳酸酯的膜。
合适的显示膜原则上是市场上可获得的，其中，三乙酰纤维素、聚甲基丙烯酸甲酯或聚碳酸酯被用作常见的载体材料。这些材料相对玻璃片材仅显现出非常低的粘附性且由于该原因被嵌入在热塑性复合膜之间，其中，这样的层堆叠的无气泡的排气设计困难，即使在复合片材的边缘区域中没有集流器。
特别优选地，功能膜是可被用作HUD膜的反射膜。该反射膜是无金属的且适合于反射入射到膜上的p偏振光线的至少5%、优选地10%至50%、特别优选地15%至30%、尤其地20%至25%。这鉴于良好的HUD图像而言是特别有利的。
反射膜优选具有在20μm(微米)与120μm之间、特别优选地在30μm与90μm之间、非常特别优选地在50μm与75μm之间的厚度。
反射膜优选是基于聚对苯二甲酸乙二醇酯(PET)的膜，其被涂层以基于PET和/或聚萘二甲酸乙二醇酯(PEN)的共聚物层堆叠。该涂层优选被涂覆在内部空间侧表面、也就是说面对车辆内部空间的表面上。例如在US No. 5,882,774 A中描述了合适的反射膜。
尤其在作为HUD膜的所描述的反射膜或漫反射显示膜中存在如下的较大需求：将这些功能同时与需要电压供应的元件集成在复合片材中。在此值得一提的是例如可加热的复合片材，其同时具有HUD膜或漫反射显示膜。
根据本发明的复合片材的至少一个集流器使得在复合片材中的电气元件的电压供应成为可能，其中，集流器相对功能膜的根据本发明的间距才完全使得将电气元件与功能膜组合成为可能。
优选地，复合片材包括至少两个集流器。在此，集流器优选被安装在复合片材的环绕的棱边的两个相对而置的截段处。以该方式可在电气元件的相对而置的截段处施加电压。
优选地，至少一个集流器被安装在导电层上，与该导电层导电地接触。特别优选地，至少两个集流器导电地在导电层上接触，其中，两个集流器在复合片材的边缘区域中以相对功能膜的环绕的棱边5mm至50mm的间距布置。在此相应地考虑在集流器与功能膜的相对所述集流器最靠近的棱边之间的最短间距。
导电层可借助于不同的对于专业人士而言已知的技术被带入到复合片材中。优选地，导电层被安装在载体膜上或被直接安装在复合片材的片材上。
导电层优选被面式地安装在外片材的内部空间侧表面或内片材的外侧表面上。优选地，导电层是加热层。在此，导电层具备至少两个集流器，其优选布置在复合片材的环绕的棱边的相对而置的截段处。在至少两个集流器之间施加电压时，导电层被电流流经且在这种情况下被加热。
如果根据本发明的功能膜是作为HUD膜的反射膜或漫反射显示膜，则导电层优选布置在外片材的内部空间侧表面上。这具有如下优点，即，导电层不影响被投影到功能膜上的图像。
带有导电层的玻璃对于专业人士而言是已知的。原则上，可通过集流器被导电接触的每个导电层可与本发明结合地使用。
导电层包含至少一种金属、金属合金或透明的传导氧化物，优选透明的传导氧化物，且具有10nm至2μm的厚度。导电层优选是透明的。此处，透明意味着对于电磁辐射、优选300nm至1,300nm波长的电磁辐射并且尤其对于可见光而言是可穿透的。合适的导电层例如由WO03/024155、US2007/0082219A1、US2007/0020465A1、WO2013/104438或WO2013/104439、DE 20 2008 017 611 U1、EP 0 847 965 B1或WO2012/052315 A1已知。所述导电层典型地包含一个或多个(例如两个、三个或四个)导电的功能性单层。功能性单层优选包含至少一种金属(例如银、金、铜、镍和/或铬)或金属合金。功能性单层特别优选地包含金属的至少90重量百分比、尤其地金属的至少99.9重量百分比。功能性单层可由金属或金属合金构成。功能性单层特别优选地包含银或含银合金。这样的功能性单层具有特别有利的导电性，同时在可见光的光谱范围中透射率较高。功能性单层的厚度优选为5nm至50nm，特别优选地为8nm至25nm。在该厚度范围中实现了在可见光的光谱范围中的有利地较高的透射率和特别有利的导电性。
集流器包括优选包含银的导电结构且例如具有5μm至40μm的厚度。集流器的宽度优选为0.5mm至30mm、特别优选地为1mm至20mm。集流器优选以相对复合片材的环绕的棱边的最靠近的截段0.5mm至20cm的间距被安装。
集流器被设置用于与外部电压源相连接，其中，由于电势差发生经过导电层的电流。
集流器的安装可尤其通过铺设、印刷、钎焊或粘贴实现。
在优选的实施形式中，集流器构造成被印刷和被烧入的传导结构。被印刷的集流器包含至少一种金属、优选银。导电性优选经由包含在集流器中的金属颗粒、特别优选地经由银颗粒实现。金属颗粒可处在有机和/或无机的基质(例如浆料或油墨)中，优选地作为带有玻璃料的烧制的丝网印刷浆料。被印刷的集流器的层厚度优选为5μm至40μm、特别优选地8μm至20μm且非常特别优选地10μm至15μm。带有这些厚度的被印刷的集流器在技术上可容易地实现且具有有利的载流能力。
在另一优选的实施形式中，集流器构造成导电膜的条带。集流排于是例如包含至少铝、铜、镀锡铜、金、银、锌、钨和/或锡或其合金。该条带优选具有10μm至500μm、特别优选地30μm至300μm的厚度。由具有这些厚度的导电膜制成的集流器在技术上易可容易实现并且具有有利的载流能力。该条带可以与导电层例如经由焊料、经由导电粘合剂或导电胶带，或通过直接铺设而导电连接。为了改善导电连接，例如可以在导电层和集流器之间布置含银浆料。
热塑性中间层优选包括至少第一热塑性复合膜和第二热塑性复合膜，功能膜被放入在其之间。第一热塑性复合膜和第二热塑性复合膜布置在功能膜的上方和下方并且包围功能膜。第一热塑性复合膜连接功能膜与外片材而第二复合膜连接功能膜与内片材。
第一热塑性复合膜和第二热塑性复合膜可彼此独立地至少包含聚乙烯醇缩丁醛(PVB)、乙烯醋酸乙烯酯(EVA)、聚氨酯(PU)或其混合物或共聚物或衍生物，优选聚乙烯醇缩丁醛(PVB)。
第一热塑性复合膜和第二热塑性复合膜可彼此独立地由单个膜构造亦或由多于一个膜构造。
第一热塑性复合膜和第二热塑性复合膜可为20μm(微米)与2mm之间厚。第一热塑性复合膜和/或第二热塑性复合膜可例如为0.2mm至2mm、特别优选地0.3mm至1mm(例如0.38mm或0.76mm)厚。第一热塑性复合膜的厚度和第二热塑性复合膜的厚度优选在整个长度上是恒定的，因此中间层具有矩形横截面。复合膜因此不是楔形膜。如果第一热塑性复合膜或第二热塑性复合膜是带有声学阻尼特性的功能性复合膜，则其优选为0.51mm或0.84mm厚。
在特别优选的实施形式中，功能膜是作为HUD膜的反射膜或漫反射显示膜，其中，第一热塑性复合膜具有200μm至1000μm、优选地300μm至850μm的厚度，而第二热塑性复合膜在10μm与120μm之间、优选在15μm与90μm之间、特别优选地在20μm与75μm之间厚。在复合片材作为机动车的抬头显示器或漫射显示器的用途中，一般而言投影仪被安装在仪表板区域中且图像被投影到内片材的内部空间侧表面上。在此，第二热塑性复合膜处在投影仪与功能膜之间的光路中。如果第二热塑性复合膜尽可能薄地实施，则这鉴于所投影的图像的图像质量而言是有利的。
可选地，第一热塑性复合膜或第二热塑性复合膜或不仅第一热塑性复合膜而且第二热塑性复合膜是功能性中间层。在此，“功能性中间层”表示具有至少一种特殊功能、尤其声学功能、颜色功能、日光功能或这些功能的组合的复合膜。
在一种实施形式中，仅第一热塑性复合膜或仅第二热塑性复合膜是功能性中间层。然而也可行的是，不仅第一热塑性复合膜而且第二热塑性复合膜是功能性中间层，其中，这些功能性中间层可具有相同的或优选不同的功能。
在特别优选的实施形式中，第一热塑性复合膜和/或第二热塑性复合膜是带有声学阻尼特性的功能性中间层。这样的声学阻尼复合膜典型地由至少三层构成，其中，中间层具有比包围它的外层更高的塑性或弹性，例如由于更高比例的增塑剂。
已经证实为特别有利的是，连接复合膜与外片材的第一热塑性复合膜实施成声学阻尼复合膜。由此得出复合片材的有利的声学特性。
声学阻尼复合膜一般而言经由所谓的机械阻抗测量(MIM，mechnanicalimpedance measurement)来表征。在此其是可在ISO 16940中查阅到的标准化方法，根据其可通过测量固有频率计算阻尼。根据该标准，待检查的声学阻尼复合膜被层压在厚度2.1mm的两个玻璃板之间，以便于在不同玻璃厚度的情形中使得相应的比较成为可能。因此使得对于专业人士能够依据众所周知的标准化测量方法来选择合适的中间层。
最早在制成复合玻璃之后一个月执行机械阻抗测量。此外，声学阻尼复合膜本身最早在其制成之后一个月与2.1mm厚度的两个玻璃片材被层压成复合玻璃。由此确保如下，即，在测量的时刻已构造有稳定的状态。
在本发明的优选的实施形式中，声学阻尼复合膜被用作第一复合膜，在其中适用如下，即，由带有相应2.1mm厚度的两个玻璃板(在其之间层压有声学阻尼复合膜)构成的带有25mm x 300mm的表面的复合玻璃片材的第一模态的阻尼系数η1和第二模态的阻尼系数η2在根据ISO 16940的机械阻抗测量(MIM)的情形中在20ºC的温度下为η1≥0.20且η2≥0.25、优选地η1≥0.25且η2≥0.30、特别优选地η1≥0.25且η2≥0.35。
优选地，功能膜在片材表面的至少80%上延伸。尤其地，功能膜全面式地(除了环绕的边缘区域之外)布置在第一热塑性中间层与第二热塑性中间层之间，该环绕的边缘区域作为通信窗口应确保电磁辐射穿过复合片材的传输，从而因此在该处优选不布置功能膜。在其中设置有集流器的区域中，在功能膜与集流器之间的间距根据本发明来实施。在沿着复合片材的环绕的棱边的剩余区域中，功能膜优选在环绕的边缘区域中被去除。在其中优选地未布置功能膜的环绕的边缘区域具有例如直至20cm的宽度、尤其20mm的宽度。其也防止功能膜相对周围大气的直接接触，从而保护在复合片材内的功能膜免受腐蚀和损伤。
在一种实施形式中，功能膜在整个片材表面上(除了集流器的在其中适用根据本发明的间距的区域之外)延伸。
根据本发明的复合片材可额外包括尤其由深色、优选黑色的搪瓷构成的掩蔽印刷(Abdeckdruck)。掩蔽印刷尤其是***的、也就是说呈框状的掩蔽印刷。***的掩蔽印刷首先充当用于复合片材的装配粘合剂的紫外线防护。掩蔽印刷可以不透明地且全面式地构造。掩蔽印刷也可至少截段式地半透明地、例如作为点网格、条纹网格或方格网格来构造。备选地，掩蔽印刷也可具有梯度，例如从不透明的覆盖至半透明的覆盖。在优选的实施形式中，掩蔽印刷如此地构造，使得反射膜的侧棱边在朝向复合片材俯视时被掩蔽印刷覆盖。如果复合片材具有通讯、传感器或摄像头窗口，则掩蔽印刷优选在片材中心的方向上被增大以通讯、传感器或摄像头窗口，从而使得围绕通讯、传感器或摄像头窗口的(多个)凹部的切割棱边也被掩蔽印刷覆盖。
掩蔽印刷通常被涂覆在外片材的内部空间侧表面上或在内片材的内部空间侧表面上。
优选地，功能膜的环绕的棱边被复合片材的不透明的掩蔽印刷覆盖。因为复合片材的集流器处在功能膜的环绕的棱边与复合片材的环绕的棱边之间，所以所述集流器同样被掩模印刷覆盖。这导致集流器与功能膜的棱边的在视觉上吸引人的粘合(Kaschierung)。
外片材和/或内片材可具有抗反射涂层、抗粘附涂层、抗划伤涂层、光催化涂层、防晒涂层和/或低辐射涂层。
外片材和内片材优选由玻璃制成，尤其由钠钙玻璃，这对于窗片材而言是常见的。片材原则上然而也可由其它的玻璃类型(例如硼硅酸盐玻璃、石英玻璃、铝硅酸盐玻璃)或透明塑料(例如聚甲基丙烯酸甲酯或聚碳酸酯)制成。外片材和内片材的厚度可较宽地变化。优选地使用具有在0.8mm至5mm、优选1.4mm至2.5mm的范围中的厚度的片材，例如带有1.6mm或2.1mm标准厚度的片材。然而也可行的是，外片材和/或内片材具有0.55mm或0.7mm的厚度。
外片材和内片材彼此独立地可以是透明的且无色的，然而也可以是着色的或有色的。在优选的设计方案中，穿过复合玻璃的总透射率为大于70%。“总透射率”的概念涉及通过ECE-R 43附录3的第9.1节所确定的用于测试机动车片材的透光性的方法。
外片材和内片材可彼此独立地未被预加应力、被部分预加应力或被预加应力。要是片材中的至少一个具有预应力，则该预应力可以是热的或化学的预应力。
根据本发明的复合片材优选在空间的一个或多个方向上弯曲，如对于机动车片材而言常见的那样，其中，典型的曲率半径处在大约10cm至大约40m的范围中。根据本发明的复合片材然而同样可以是平面的，例如当其设置作为用于公共汽车、火车或拖拉机的片材时。
在一种可能的实施形式中，第一热塑性复合膜和/或第二热塑性复合膜是带有颜色功能的功能性中间层。这意味着中间层是有色的或着色的。在此，中间层可全面式地着色或上色。备选地，中间层同样可具有颜色梯度或彩色图案。在设置作为挡风玻璃的复合片材中，上色或着色如此地构造，使得复合片材在380nm至780nm的光谱范围中具有大于70%的光透射率。在设置作为车顶片材或后侧窗片材的复合片材中，上色或着色也可更深地构造且复合片材因此在380nm至780nm的光谱范围中可具有70%或更低的光透射率。
第一热塑性复合膜和/或第二热塑性复合膜也可以是在其中组合两种或更多种功能特性的功能性中间层，例如带有颜色功能和/或日光功能的声学阻尼特性。
根据本发明的复合片材的特别优选的设计方案优选包括功能膜，其是作为HUD膜的反射膜或漫反射显示膜，优选作为HUD膜的反射膜。复合片材具备至少两个集流器，其导电地接触导电层，且所述至少两个集流器相应地沿着复合片材的环绕的棱边以相对功能膜的根据本发明的间距被安装。导电层被涂覆在外片材的内部空间侧表面上且优选设置作为加热层。集流器沿着复合片材的环绕的棱边的相对而置的截段布置。
带有作为HUD膜的功能膜的根据本发明的复合片材的这种优选的设计方案可以配备有投影仪，其中，获得用于抬头显示器(HUD)的投影组件。这种投影组件特别是被使用在机动车中，其中，复合片材优选是挡风玻璃。如在HUD中常见的那样，投影仪照亮挡风玻璃的一个区域，在其处辐射在观察者(驾驶员)的方向上被反射，由此产生观察者由其来看在挡风玻璃之后感知的虚拟图像。挡风玻璃的可被投影仪照射的区域被称作HUD区域。投影仪的辐射方向典型地可通过镜子被改变(尤其竖直地改变)，以便于将投影适配于观察者的身高。观察者的眼睛在给定镜子姿态的情形中须所处的区域被称作眼动范围窗口(Eyeboxfenster)。该眼动范围窗口可通过调节镜子被竖直地移动，其中，整个由此可接近的区域(也就是说所有可能的眼动范围窗口的叠加)被称作眼动范围。处在眼动范围内的观察者可感知虚拟的图像。因此当然意味着如下，即，观察者的眼睛须处在眼动范围内，而不是例如整个身体。
根据HUD领域的所使用的专业术语对于专业人员而言是普遍已知的。对于详尽阐述可参考慕尼黑工业大学计算机科学研究所的Alexander Neumann的论文《用于测试抬头显示器的基于仿真的测量技术》(Munich: University Library of the TechnicalUniversity of Munich , 2012)，尤其第2章“抬头显示器”。
p偏振辐射在投影仪的总辐射处的比例优选至少为70%。在用于抬头显示器的投影组件的有利的实施形式中，p偏振辐射在投影仪的总辐射处的比例至少为80%；特别优选地，p偏振辐射在投影仪的总辐射处的比例为80%或100%，非常特别优选地为100%。
在此，偏振方向的说明涉及辐射在复合片材上的入射平面。用p偏振辐射表示其电场在入射平面中振荡的辐射。用s偏振辐射表示其电场垂直于入射平面振荡的辐射。入射平面由入射矢量和在HUD区域的几何中心的复合片材的面法线展开。
投影仪的辐射优选以50º至80º、尤其地60º至70º的入射角入射到复合片材上，典型地例如65º，如其在HUD投影组件中常见的那样。入射角是投影辐射的入射矢量与在HUD区域几何中心的面法线之间的角度。因为对于HUD投影组件而言典型的大约65º的入射角度相对靠近用于空气-玻璃过渡(57.2º，钠钙玻璃)的布鲁斯特角，所以由投影仪所发射的辐射的p偏振辐射分量几乎不被片材表面反射。然而，在复合片材中所包含的反射膜针对p偏振辐射的反射被优化。以该方式，由观察者所感知的图像不或仅以非常小的程度被重影图像扭曲。因此可省去呈楔形的中间层。
在投影组件的一种实施形式中，由投影仪发射的且入射到复合片材的反射膜上的p偏振光线的10%至50%、优选地15%至30%、特别优选地20%至25%由反射膜在观察者的方向上被反射。
此外，本发明涉及一种用于制造根据本发明的复合片材的方法，至少包括如下步骤：
a)提供内片材或外片材，
b)安装至少一个集流器，
c)铺设带有功能膜的热塑性中间层，和
d)铺设外片材或内片材以便封闭层堆叠，并且将其层压成复合片材，
其中，在步骤c)之前或期间进行功能膜的截短且功能膜的环绕的棱边在截短之后相对至少一个集流器具有5mm至50mm的间距。
优选地，在步骤a)之前或期间导电层被涂覆在外片材的内侧表面或内片材的外侧表面上且至少一个集流器被导电地涂覆在导电层上。导电层借助于对于专业人士而言已知的方法被涂覆。优选地，导电层通过物理气相沉积(PVD)被涂覆到片材表面上，特别优选地通过阴极溅射(“溅射”)、非常特别优选地通过磁场辅助阴极溅射(“磁控溅射”)。导电层在复合片材的层压之前被涂覆。代替将涂层涂覆到片材表面上，所述涂层原则上也可在载体膜上被提供。
带有功能膜的热塑性中间层在步骤c)中以一个或多个步骤被铺设。优选地，热塑性中间层至少包括第一热塑性复合膜和第二热塑性复合膜，在其之间置入功能膜。功能膜可在步骤c)中铺设中间层之前被置入在热塑性复合膜之间。在该情况中，带有功能膜的热塑性中间层作为三层在一个步骤中被铺设。可选地，热塑性复合膜和功能膜也可单独地在步骤c)中被铺设，其中，带有嵌入的功能膜的中间层直接在步骤c)中得到。
功能膜在步骤c)之前或期间的截短可借助于专业上常见的方法(例如激光切割方法)亦或借助于刀刃的裁剪实现。
优选地，在步骤b)期间或之后且在步骤d)之前排气结构被压入到至少一个集流器中。该排气结构进一步使得层堆叠的排气变得容易。排气结构可例如借助于结构化的滚轮、带齿的滚动工具或类似的工具被带入到至少一个集流器中。
根据本发明的复合片材可在步骤d)中通过本身已知的方法被层压。外片材、内片材和处在其间的功能膜经由热塑性复合膜被彼此层压，例如通过高压釜法、真空袋法、真空环法、压延法、真空层压机或其组合。在此，外片材和内片材的连接通常在热、真空和/或压力的作用下实现。
要是复合片材是弯曲的，则外片材和内片材优选在层压之前经受弯曲过程。优选地，外片材和内片材共同地(也就是说同时且通过相同的工具)被完全一致地弯曲，因为由此片材的形状对于之后实现的层压而言被最佳地彼此协调。对于片材弯曲工艺而言的典型温度例如为500ºC至700ºC。
上面所描述的对于该方法的实施方案同样相应地适用于根据本发明的复合片材且反之亦然。
本发明还包括根据本发明构造的复合片材在机动车、优选乘用车中作为挡风玻璃的用途，所述复合片材用作用于抬头显示器的投影组件的投影面。根据本发明构造的复合片材也可被用作在机动车、优选乘用车中的侧窗片材或车顶片材。在这些情况中，复合片材也可充当用于抬头显示器的投影组件的投影面。上面所描述的优选的设计方案相应地适用于该用途。
附图说明
接下来依据附图和实施例作进一步阐述本发明。附图是示意性图示而非按比例。附图绝不限制本发明。
其中：
图1显示了作为带有HUD区域的抬头显示器的根据本发明的复合片材的俯视图，
图2显示了包括沿着截面线AA'穿过图1的复合片材的横截面中的图1的复合片材的投影组件，
图3显示了带有热塑性中间层3的详细层结构的图1的复合片材，
图4显示了根据本发明的方法的一种实施形式。
具体实施方案
图1以俯视图显示了作为挡风玻璃、尤其作为乘用车的挡风玻璃的根据本发明的复合片材1。复合片材1由经由热塑性中间层3彼此相连接的外片材2和内片材6构建。在热塑性中间层3中嵌入有功能膜4。功能膜4是作为HUD膜的反射膜。复合片材具有HUD区域B，在其中借助于投影仪可将图像投影到挡风玻璃上。复合片材1的环绕的棱边K被划分成下棱边U、上棱边O和两个彼此相对而置的侧棱边S，所述侧棱边将上棱边O和下棱边U彼此连接。复合片材1的下棱边U向下沿乘用车的发动机的方向布置，该复合片材的上棱边O向上沿车顶的方向布置。侧棱边S在复合片材1在机动车中的安装状态中沿着A柱伸延。外片材2在安装位置中面对外部环境，内片材6面对车辆内部空间。沿着上棱边O和下棱边U相应地伸延有集流器5。集流器5接触导电层7。导电层7是加热层。反射膜4被如此地置入在复合片材1中，使得反射膜4反射入射到膜上的p偏振光线的例如20%至25%。功能膜4具有环绕的棱边U，其相比复合片材1的环绕的棱边K在复合片材1的面中心的方向上缩进。在功能膜4的环绕的棱边U与相邻于棱边U的相应的棱边截段的集流器5之间的间距x沿着整个集流器5相应地为20mm。复合片材1绝不具有气穴，尤其地绝不会在集流器5的区域中发现气穴或缺陷。
图2显示了用于包括图1的复合片材1的HUD的投影组件，其中，该投影组件被显示作为沿着根据图1的复合片材的截面线A-A'的横截面。此外，投影组件包括投影仪12，其朝向复合片材1的区域指向。在该通常被称作HUD区域B的区域中，通过投影仪12可产生图像，其由观察者11(车辆驾驶员)在复合片材1的与其背对的侧面上被感知作为虚拟图像，当观察者的眼睛处在所谓的眼动范围E内时。投影仪12的辐射是p偏振的，尤其大致纯p偏振的。因为投影仪12以接近布鲁斯特角的大约65º的入射角照射挡风玻璃1，所以投影仪的辐射仅微不足道地在复合片材1的外表面I,IV上被反射。与之相反，作为功能膜4的反射膜针对p偏振辐射的反射被优化。其充当用于产生HUD投影的投影仪12的辐射用的反射面。
图3显示了带有热塑性中间层3的详细的层结构的图1的复合片材。外片材2和内片材6例如由钠钙玻璃构成。外片材2具有在安装位置中面对外部环境的外侧表面I(也被称作外片材的外侧)，和在安装位置中面对内部空间的内部空间侧表面II(也被称作外片材的内侧)。同样地，内片材6具有在安装位置中面对外部环境的外侧表面III(也称为内片材的内侧)和在安装位置中面对内部空间的内部空间侧表面IV(也称为内片材的外侧)。外片材2例如具有2.1mm的厚度，内片材6具有1.6mm的厚度。在外片材2的内部空间侧表面II上溅射有以加热层形式的导电层7。集流器5电气接触导电层7，其中，复合片材1通过在集流器5处施加电压可被加热。第一热塑性复合膜3a由唯一一层热塑性材料构造，例如由带有0.76mm厚度的PVB膜或带有0.81mm厚度的带有声学阻尼特性的PVB膜。第二热塑性复合膜3b构造成带有0.38mm厚度的PVB膜。功能膜4是布置在第一热塑性复合膜3a与第二热塑性复合膜3b之间的反射膜。第一热塑性复合膜3a和第二热塑性复合膜3b被熔合成热塑性中间层3且包围嵌入在其中的功能膜4。反射膜4是无金属的且适合于反射入射到膜4上的p偏振光线的至少5%、例如20%至25%。反射膜4例如为50μm至75μm厚且例如是基于PET的膜，其被涂层以基于PET和PEN的共聚物层堆叠。反射膜4全面式地(除了环绕的边缘区域R之外)布置在第一热塑性中间层3与第二热塑性中间层5之间。在集流器5的区域中，在集流器5与功能膜4的环绕的棱边U的最靠近的截段之间的间距相应地为20mm。在剩余的环绕的边缘区域R中，在带有相对复合片材1的环绕的棱边K的20mm宽度的区域中未布置有反射膜4。复合片材1具有不透明的掩蔽印刷(未显示)，其粘合环绕的棱边U与集流器5。
图4显示了根据本发明的方法的一种实施形式，至少包括如下步骤：
I提供内片材6或外片材2，其中，在外片材2的内部空间侧表面II或内片材6的外侧表面III上安装有导电层7，
II将至少一个集流器5安装在导电层7上，其中，至少一个集流器5导电地接触导电层7，
III将第一热塑性复合膜3a铺设到外片材2的内部空间侧表面II上或将第二热塑性复合膜3b铺设到内片材6的外侧表面III上，
IV铺设功能膜4，其中，功能膜4的环绕的棱边U相对最靠近的集流器5具有5mm至50mm的间距，
V铺设第二热塑性复合膜3b或铺设第一热塑性复合膜3a，
VI利用外片材2或内片材6封闭层堆叠，并且将其层压成复合片材1。
步骤III至V可在一个或多个步骤中进行。功能膜4的截短可在步骤III至V之前或期间进行。
附图标记列表：
1 复合片材
2 外片材
3 热塑性中间层
3a 第一热塑性复合膜
3b第二热塑性复合膜
4 功能膜
5 集流器
6 内片材
7 导电层
10投影组件
11 观察者、车辆驾驶员
12 投影仪
K 复合片材1的环绕的棱边
U 功能膜4的环绕的棱边
x 在功能膜4的环绕的棱边U与集流器5之间的间距
R 环绕的边缘区域
B 复合片材1的HUD区域
E 眼动范围
O 复合片材1的上棱边
U 复合片材1的下棱边
S 复合片材1的侧棱边
(I) 外片材2的外侧的、背对中间层3的表面
(II) 外片材2的内部空间侧的、朝向中间层3的表面
(III) 内片材6的外侧的、朝向中间层3的表面
(IV) 内片材6的内部空间侧的、背对中间层3的表面。

Claims (15)

1.一种带有功能膜(4)的复合片材(1)，至少包括所述复合片材(1)的环绕的棱边(K)、所述功能膜(4)的环绕的棱边(U)、至少一个集流器(5)、带有外侧表面(I)和内部空间侧表面(II)的外片材(2)、带有外侧表面(III)和内部空间侧表面(IV)的内片材(6)以及连接所述外片材(2)的内部空间侧表面(II)与所述内片材(6)的外侧表面(III)的热塑性中间层(3)，其中，
- 所述功能膜(4)被嵌入在所述热塑性中间层(3)中，
- 所述功能膜(4)的环绕的棱边(U)相对所述复合片材(1)的环绕的棱边(K)在所述复合片材(1)的面中心的方向上缩进，
- 所述至少一个集流器(5)布置在所述外片材(2)的内侧表面(II)与所述内片材(6)的外侧表面(III)之间，并且在所述复合片材(1)的边缘区域(R)中在所述复合片材(1)的环绕的棱边(K)与所述功能膜(4)的环绕的棱边(U)之间伸延，且
- 沿着所述至少一个集流器(5)在所述集流器(5)与所述功能膜(4)的环绕的棱边(U)之间的间距x为5mm与50mm之间。
2.根据权利要求1所述的复合片材(1)，其中，沿着所述至少一个集流器(5)在集流器(5)与所述功能膜(4)的环绕的棱边(U)之间的间距为10mm至30mm、优选地15mm至25mm。
3.根据权利要求1或2所述的复合片材(1)，其中，所述功能膜(4)包括至少一个基于聚对苯二甲酸乙二醇酯(PET)、聚乙烯(PE)、聚甲基丙烯酸甲酯(PMMA)、三乙酰纤维素(TAC)和/或聚碳酸酯和/或其共聚物或混合物的载体膜，优选地包括基于聚对苯二甲酸乙二醇酯(PET)的载体膜。
4.根据权利要求1至3中任一项所述的复合片材(1)，其中，所述功能膜(4)是反射膜，其无金属且适合用于反射入射到所述膜上的p偏振光线的至少5%、优选10%至50%、特别优选地15%至30%、尤其20%至25%。
5.根据权利要求4所述的复合片材(1)，其中，作为功能膜(4)的反射膜为20μm(微米)与120μm之间、优选地30μm与90μm之间、特别优选地50μm与75μm之间厚。
6.根据权利要求4或5所述的复合片材(1)，其中，作为功能膜(4)的反射膜是基于聚对苯二甲酸乙二醇酯(PET)的膜，其被涂层以基于PET和/或聚萘二甲酸乙二醇酯(PEN)的共聚物层堆叠。
7.根据权利要求1至6中任一项所述的复合片材(1)，其中，所述至少一个集流器(5)被安装在导电层(7)上且电气接触所述导电层。
8.根据权利要求7所述的复合片材(1)，其中，所述导电层(7)被面式地安装在所述外片材(2)的内部空间侧表面(II)或所述内片材(6)的外侧表面(III)上。
9.根据权利要求1至8中任一项所述的复合片材(1)，其中，所述热塑性中间层(3)至少包括第一热塑性复合膜(3.1)和第二热塑性复合膜(3.2)，在其之间置入所述功能膜(4)。
10.根据权利要求9所述的复合片材，其中，所述第一热塑性复合膜(3.1)具有200μm至1000μm、优选300μm至850μm的厚度，而所述第二热塑性复合膜(3.2)为10μm与120μm之间、优选地15μm与90μm之间、特别优选地20μm与75μm之间厚。
11.根据权利要求1至10中任一项所述的复合片材，其中，所述第一热塑性复合膜(3.1)是带有声学阻尼特性的膜、吸收红外辐射的中间层、有色的中间层或其组合。
12.一种用于制造根据权利要求1至11中任一项所述的复合片材(1)的方法，其中，
a)提供内片材(6)或外片材(2)，
b)安装所述至少一个集流器(5)，
c)铺设带有功能膜(4)的热塑性中间层(3)，且
d)利用外片材(2)或内片材(6)封闭层堆叠，并且将其层压成复合片材(1)，
其中，在步骤c)之前或期间进行所述功能膜(4)的截短，且所述功能膜(4)的环绕的棱边(U)在截短之后相对所述集流器(5)具有5mm至50mm的间距。
13.根据权利要求12所述的方法，其中，在步骤a)之前或期间将导电层(7)涂覆在所述外片材(2)的内侧表面(II)或所述内片材(6)的外侧表面(III)上，并且将所述至少一个集流器(5)导电地涂覆在所述导电层(7)上。
14.根据权利要求12或13所述的方法，其中，在步骤b)期间或之后且在步骤d)之前将通风结构压入到所述至少一个集流器(5)中。
15.根据权利要求1至11中任一项所述的复合片材(1)在机动车、优选乘用车中优选作为挡风玻璃的用途。
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WO2017204103A1 (ja) 2016-05-24 2017-11-30 富士フイルム株式会社 透明フィルム、透明スクリーンおよび画像表示システムならびに透明ポスター

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