Abstract
A laminated pane having at least one integrated electrical attachment part, includes an inner pane having an inner side and an outer side, an outer pane having an inner side and an outer side, a thermoplastic intermediate layer, which joins the inner side of the outer pane and the inner side of the inner pane to one another, and at least one recess in the inner pane and/or the outer pane, wherein the electrical attachment part is inserted into the recess and is situated completely within the laminated pane, the laminated pane is a vehicle laminated pane having a three-dimensional bend, and the recess is introduced into the inner pane and/or the outer pane by laser processes.
Claims
1. A laminated pane having at least one integrated electrical attachment part comprising: an inner pane having an inner side and an outer side, an outer pane having an inner side and an outer side, a thermoplastic intermediate layer, which joins the inner side of the outer pane and the inner side of the inner pane to one another, and at least one recess of the inner pane and/or of the outer pane, wherein the electrical attachment part is inserted into the recess and is situated completely within the laminated pane, the laminated pane is a vehicle laminated pane having a three-dimensional bend, and the recess is introduced into the inner pane and/or the outer pane by laser processes.
2. The laminated pane according to claim 1, wherein the recess has an angular contour, at least in sections.
3. The laminated pane according to claim 1, wherein the recess is implemented as a through-going opening in at least one subregion and as a non-through-going partial recess in at least one other subregion.
4. The laminated pane according to claim 3, wherein the subregion of the recess that is implemented as a non-through-going partial recess serves to accommodate fastening elements.
5. The laminated pane according to claim 1, wherein the inner edge of the recess is sloped and assumes an angle α of 20° to 80° relative to an adjacent pane surface.
6. The laminated pane according to claim 1, wherein the depth of the at least one recess is less, at least in sections, than the thickness of the inner pane or the outer pane in which the recess is introduced.
7. The laminated pane according to claim 6, wherein the thickness of the inner pane or the outer pane in which the recess is introduced is between 1.5 mm and 30.0 mm, and the depth of the recess is between 0.8 mm and 15.0 mm.
8. The laminated pane according to claim 1, wherein the at least one electrical attachment part is mounted in a recess on the outer side of the inner pane.
9. The laminated pane according to claim 8, wherein the at least one electrical attachment part or a cover of the attachment part is reversibly attached in a sloped region of the inner edge of the recess.
10. The laminated pane according to claim 1, wherein the at least one electrical attachment part is mounted in a recess on the inner side of the inner pane and/or the inner side of the outer pane.
11. The laminated pane according to claim 1, wherein the at least one electrical attachment part has at least one electrical supply line, which runs in the thermoplastic intermediate layer between the inner side of the inner pane and the inner side of the outer pane.
12. The laminated pane according to claim 1, wherein the at least one electrical attachment part is electrically conductively contacted via an electrically conductive layer on the inner side of the outer pane, the inner side of the inner pane, and/or the outer side of the inner pane.
13. The laminated pane according to claim 1, wherein the at least one electrical attachment part is a sensor, a detector, a camera, a display, or a light source.
14. The laminated pane according to claim 1, wherein the recess has a diameter of less than 100 mm, or has at least one edge with an edge length of less than 100 mm.
15. A method for producing a laminated pane according to claim 1, the method comprising a) providing an inner pane or an outer pane, b) producing at least one recess in the inner pane and/or the outer pane by laser processes, c) inserting an electrical attachment part into the recess, d) laminating the inner pane per step a) with an outer pane with interposition of the thermoplastic intermediate layer or laminating the outer pane per step a) with an inner pane with interposition of the thermoplastic intermediate layer, wherein the attachment part is fully embedded in the laminated pane and step c) is done before or after step d).
16. The method according to claim 15, wherein in step b), the recess is a through-going opening that is produced by laser drilling using a pulsed laser with a pulse length of less than 10 ns, a wavelength of 300 nm to 800 nm, and a power of 5 W to 100 W.
17. The method according to claim 15, wherein the recess is produced by laser ablation using a pulsed laser with a pulse length of less than 10 ns, a wavelength of 300 nm to 800 nm, and a power of 5 W to 100 W.
18. The method according to claim 15, wherein the recess is produced by a multistage laser method, comprising a first step for producing filaments using a first pulsed laser with a pulse length of less than 100 ps and a wavelength of 300 nm to 800 nm, a second step for heating the pane using a second laser in continuous wave operation with a wavelength of 1 μm to 20 μm and a third step in which the pane is cooled.
19. A method comprising utilizing a laminated pane according to claim 1 as a vehicle glazing.
20. The method according to claim 19, wherein the vehicle glazing is a windshield, roof panel, side window, or rear window.
Description
[0106] The invention is explained in detail with reference to drawings and exemplary embodiments. The drawings are schematic representations and not to scale. The drawings in no way restrict the invention. They depict:
[0107] FIG. 1 a plan view and multiple cross-sections of various embodiments of the laminated pane according to the invention with at least one recess in the form of a through-going hole,
[0108] FIG. 2 a plan view and a cross-section of another laminated pane according to the invention with a recess in the form of a through-going hole with inserted light sources, wherein the light sources are arranged on the edge of the recess,
[0109] FIG. 3 a plan view of a detail of another laminated pane according to the invention with recess with inserted light sources, wherein the light sources illuminate various symbols in the pane,
[0110] FIG. 4 a plan view and multiple cross-sections of various embodiments of the laminated pane according to the invention with partial, non-through-going, recesses,
[0111] FIG. 5 an embodiment of the method according to the invention.
[0112] FIG. 6 an embodiment and multiple detailed views of a laminated pane according to the invention as a roof panel of a motor vehicle with inserted light source and lens.
[0113] FIG. 1a, 1b, 1c, and 1d depict a plan view and multiple cross-sections of various embodiments of the laminated pane according to the invention with at least one recess in the form of a through-going hole, in which an electrical attachment part is integrated. FIG. 1a depicts a plan view of the laminated pane 1 comprising an inner pane 3 and an outer pane 4 that are laminated together via a thermoplastic intermediate layer 5. The inner pane 3 has an outer surface IV and an inner surface III. The outer pane has an inner surface II and an outer surface I. The thermoplastic intermediate layer 5 joins the inner surface III of the inner pane 3 and the inner surface II of the outer pane 4. The laminated pane 1 is used as a windshield of a motor vehicle. The outer pane 4 and the inner pane 3 are made of soda lime glass. The thermoplastic intermediate layer 5 is a polyvinyl butyral film with a thickness of 0.76 mm measured prior to the lamination operation. The laminated pane 1 has a recess 6 in which an electrical attachment part 2 is embedded. FIGS. 1b, 1c, and 1d depict various embodiment variants of the basic structure of FIG. 1a in detail. Possible covers 9 or electrical supply lines 7 are not depicted in FIG. 1a, for simplification. The contour of the recess 6 corresponds to an isosceles trapezoidal shape, wherein the base and the legs of the trapezoid have a length of 1.5 cm and the side of the trapezoid opposite the base has a length of 0.7 cm.
[0114] FIG. 1b depicts a cross-section of the basic structure of FIG. 1a along the cutting line AA′. The outer pane 4 and the inner pane 3 have a thickness of 2.1 mm. The inner pane 3 has a recess 6 in the form of a through-going hole. The recess 6 thus extends continuously from the outer side IV of the inner pane 3 all the way to the inner side III of the inner pane 3. An electrical attachment part 2 is embedded in the recess 6, wherein the attachment part 2 is fully integrated into the laminated pane and does not protrude beyond it in any dimension. The attachment part 2 is situated within the recess 6 and protrudes through an opening in the thermoplastic intermediate layer 5 all the way to the inner surface II of the outer pane 4. In the present exemplary embodiment, the electrical attachment part 2 is a camera with a thickness of approx. 2 mm, which was inserted into the recess 6 after lamination of the laminated pane 1. Optionally, the thermoplastic intermediate layer 5 can be removed before or after lamination, in this exemplary embodiment before lamination, in the region of the recess 6. An electrical supply line 7 of the camera is routed to the recess 6 within the thermoplastic intermediate layer 5 of the laminated pane 1. The recess 6 was created by laser drilling before the stacking of the panes and before lamination of the laminated pane 1. The cover 9 is an opaque molded plastic part that reversibly closes the recess 6 on the inner side IV of the inner pane 3. This embodiment is particularly advantageous since the electrical attachment part 2 is integrated into the laminated pane 1 in a visually appealing and inconspicuous manner and is nevertheless reversibly accessible.
[0115] FIG. 1c depicts a cross-section of the basic structure of FIG. 1a along the cutting line AA′, wherein the structure corresponds substantially to FIG. 1b. In contrast to FIG. 1b, in addition to a recess 6 of the inner pane as a through-going hole, there is also a partial recess 6 in the outer pane 4. The outer pane 4 has a thickness of 2.1 mm, while the thickness of the inner pane is 1.8 mm. The partial, non-through-going recess 6 of the outer pane 4 is introduced on the inner side II of the pane by laser ablation. All recesses are created before the stacking and lamination of the pane arrangement. The thermoplastic intermediate layer 5 has been removed in the region of the recess 6 before lamination of the laminated pane 1. The electrical attachment part 2, here, a camera, has a thickness of approx. 2.5 mm. This embodiment is advantageous when an electrical attachment part 2, whose thickness exceeds the thickness of the inner pane 3, is to be inserted reversibly.
[0116] FIG. 1d depicts a cross-section of the basic structure of FIG. 1a along the cutting line AA′, wherein the structure corresponds substantially to FIG. 1b. In contrast to FIG. 1b, the electrical attachment part 2 is a light source, here, an LED light. The beam direction of the LED is represented in FIG. 1d by an arrow that points in the direction of the vehicle interior. The cover 9 is a transparent plastic and/or glass cover including a lens arrangement that bundles the light of the inserted LED. The thickness of the inner pane 3 and of the outer pane 4 is in each case 2.1 mm, while the LED light has a thickness of 1.5 mm. The thermoplastic intermediate layer 5 has not been removed in the region of the recess 6. This embodiment is particularly advantageous when a light source that requires additional optics is to be reversibly integrated into the laminated pane.
[0117] FIGS. 2a and 2b depict a plan view and a cross-section of another laminated pane according to the invention 1 with a recess 6 in the form of a through-going hole with two electrical attachment parts inserted therein. The attachment parts 2 are light sources in the form of LED lights that are arranged on the edge of the recess 6. The laminated pane 1 comprises an inner pane 3 and an outer pane 4 that are laminated together via a thermoplastic intermediate layer 5. The inner pane 3 has an outer surface IV and an inner surface III. The outer pane has an inner surface II and an outer surface I. The thermoplastic intermediate layer 5 joins the inner surface III of the inner pane 3 and the inner surface II of the outer pane 4. The outer pane 4 and the inner pane 3 are made of soda lime glass. The thermoplastic intermediate layer 5 is a polyvinyl butyral film with a thickness of 0.76 mm measured prior to the lamination operation. The electrical attachment parts 2 are fully integrated into the inner pane 3 of the laminated pane 1 and do not protrude beyond the laminated pane 1. An electrical supply line 7 of the attachment parts 2 is routed to the recess 6 within the thermoplastic intermediate layer 5 of the laminated pane 1. The recess 6 was created by laser drilling before the stacking of the panes and before lamination of the laminated pane 1. The cover 9 is an opaque molded plastic part that reversibly closes the recess 6 on the inner side IV of the inner pane 3 and optically conceals the components situated therein. The LED lights are oriented within the recess 6 such that the emitted light is coupled into the inner pane 3 of the laminated pane 1 at the edge of the recess. Multiple patterns 8 are introduced within the inner pane 3, likewise by laser methods. The light coupled in at the recess 6 is coupled out at these locations, by which means the patterns light in the light color of the coupled-in light. Optionally, a switch that enables turning the illumination on and off can be introduced into the cover 9. The recess 6 was created by laser drilling before lamination of the laminated pane 1 and the edge of the recess 6 was polished by laser radiation. The contour of the recess 6 corresponds to a rectangle with edge lengths of 2.0 cm and 1.0 cm. The inner pane with a through-going opening has a thickness of 6 mm; the outer pane has a thickness of 4 mm. The electrical attachment parts 2 have a height of 4 mm measured along the edge of the recess 6. The laminated pane of FIGS. 2a and 2b proves to be particularly advantageous as a component of indoor or outdoor architectural glazing. However, analogous arrangements can also be implemented with the pane thicknesses customary in the automotive sector in curved motor vehicle laminated panes.
[0118] FIG. 3 depicts a detailed of another laminated pane according to the invention 1 with electrical attachment parts 2 in the form of LED lights inserted in a recess 6. These light sources illuminate various symbols of a pane. The laminated pane itself is not depicted here, but corresponds in its basic structure substantially to FIG. 1a. The design of the recess 6 can be implemented, as described by way of example in FIGS. 1, 2, and 4, as a through-going opening and/or as a non-through-going opening. The electrical attachment parts 2 are, also in this case, fully integrated into the laminated pane and do not protrude beyond this. The contour of the recess of FIG. 3 is diamond-shaped, with a light source mounted on each edge of the diamond, which illuminates, as needed, a symbol introduced in the vicinity of the recess (pattern 8). Thus, multiple light sources can be introduced into the laminated pane in the smallest space. The positioning and orientation of the light sources is advantageously not dependent on the course of the edge of the laminated pane; for example, the corners of the diamond-shaped recess can be oriented in the direction of the edges of the laminated pane.
[0119] FIGS. 4a, 4b, 4c, and 4d depict a plan view and multiple cross-sections of various embodiments of the laminated pane according to the invention 1 with at least one partial recess 6 in the form of a non-through-going hole, in which an electrical attachment part 2 is integrated. The exemplary embodiments of FIG. 4 refer to windshields of the motor vehicle. FIG. 4a depicts a plan view of the laminated pane 1 comprising an inner pane 3 and an outer pane 4 that are laminated together via a thermoplastic intermediate layer 5. The inner pane 3 has an outer surface IV and an inner surface III. The outer pane has an inner surface II and an outer surface I. The thermoplastic intermediate layer 5 joins the inner surface III of the inner pane 3 and the inner surface II of the outer pane 4. The laminated pane 1 is used as a windshield of a motor vehicle. The outer pane 4 and the inner pane 3 are made of soda lime glass. The thermoplastic intermediate layer 5 is a polyvinyl butyral film with a thickness of 0.76 mm measured prior to the lamination operation. The laminated pane 1 has a recess 6 in which an electrical attachment part 2 is embedded. FIGS. 4b, 4c, and 4d depict various embodiment variants of the basic structure of FIG. 4a in detail. Electrical supply lines 7 are not depicted in FIG. 4a, for simplification. The contour of the recess 6 corresponds to a circular hole with a diameter of 1.5 cm.
[0120] FIG. 4b depicts a cross-section of the basic structure of FIG. 4a along the cutting line CC′. The outer pane 4 has a thickness of 2.1 mm, and the inner pane 3 has a thickness of 0.8 mm. In addition to a partial recess 6 of the inner pane 3, there is also another partial recess 6 of the outer pane 4. The recess of the outer pane 4 has a depth of 1.0 mm, while the recess of the inner pane 3 has a depth of 0.5 mm. An electrical attachment part 2 is embedded in the recesses 6, with the attachment part 2 fully integrated into the laminated pane 1 and not protruding beyond it in any dimension. The attachment part 2 is situated within the recess 6 and protrudes through the thermoplastic intermediate layer 5 into the partial recess 6 of the outer pane 4. In the present exemplary embodiment, the electrical attachment part 2 is a light sensor with a thickness of approx. 1.5 mm that was inserted into the recess 6 prior to lamination of the laminated pane 1. The thermoplastic intermediate layer 5 begins to flow during the lamination operation and fills the region of the recess 6 that is not occupied by the electrical attachment part 2. An electrical supply line 7 of the camera is routed, within the thermoplastic intermediate layer 5 of the laminated pane 1, to the recess 6 and is likewise inserted into the laminate prior to lamination of the pane arrangement. The recesses 6 were created by laser ablation before the stacking of the panes and before lamination of the laminated pane 1.
[0121] The embodiment of FIG. 4b is particularly advantageous in terms of seamless integration of attachment parts in which the outer surfaces of the laminated pane are not damaged.
[0122] FIGS. 4c and 4d and depict different examples of the integration of LED lights as electrical attachment parts 2 in a laminated pane 1. The radiation direction of the LED lights can be oriented both in the direction of the vehicle interior and in the direction of the surroundings. The electrical attachment part 2 in the form of an LED light is embedded in the recess such that the attachment part 2 is fully integrated into the laminated pane 1 and protrudes beyond it in no dimension. In the present exemplary embodiments, the electrical attachment part 2 is LED lights with a thickness of approx. 1.5 mm that were inserted into the recesses 6 prior to lamination of the laminated pane 1. The thermoplastic intermediate layer 5 begins to flow during the lamination operation and fills the region of the recesses 6 that is not occupied by the electrical attachment parts 2. An electrical supply line 7 of the light sources is routed, within the thermoplastic intermediate layer 5 of the laminated pane 1, to the recess 6 and is likewise inserted into the laminate prior to lamination of the pane arrangement. The recesses 6 were created by laser ablation before the stacking of the panes and before lamination of the laminated pane 1.
[0123] The embodiment of FIG. 4c has an outer pane with a thickness of 2.1 mm and an inner pane 3 with a thickness of 0.4 mm. The outer pane 4 has on its inner side II a partial recess 6 with a depth of 1.2 mm. The LED light is embedded in this recess 6 and protrudes out of the recess 6 into the thermoplastic intermediate layer 5. The LED light shines through the thermoplastic intermediate layer 5 and the inner pane 3 in the direction of the vehicle interior. FIG. 4c illustrates a laminated pane 1 according to the invention with a highly asymmetrical thickness combination of the inner pane 3 and the outer pane 4.
[0124] FIG. 4d depicts a laminated pane 1 according to the invention with a partial recess 6 in the inner pane 3. The outer pane 4 has a thickness of 1.4 mm, while the inner pane 3 has a thickness of 1.8 mm. The inner pane 3 has, on its inner side III, a partial recess 6 with a depth of 1.1 mm. An LED light (electrical attachment part 2) with a thickness of 1.3 mm is embedded in this recess 6 and protrudes out of the recess 6 into the thermoplastic intermediate layer 5. The LED light shines through the material of the inner pane 3 remaining in the region of the recess 6 in the direction of the vehicle interior. After laser ablation of the recess 6 in the inner pane 3, the region of the recess 6, through which the light of the LED light passes, is polished by laser processes. Only after that is the LED light inserted into the recess 6 and the pane arrangement laminated.
[0125] FIG. 5 depicts an embodiment of the method according to the invention comprising the steps: [0126] I Optional: Joint congruent bending of the outer pane 4 and the inner pane 3, [0127] II Providing the inner pane 3 or the outer pane 4, [0128] IIIa Creating at least one through-going recess 6 in the inner pane 3 and/or the outer pane 4 by laser drilling or Creating at least one non-through-going partial recess 6 on the outer side IV of the inner pane 3 and/or the outer side I of the outer pane 4 by laser ablation, [0129] IIIb Creating at least one non-through-going partial recess 6 on the inner side III of the inner pane 3 and/or der inner side II of the outer pane 4 by laser ablation, [0130] IV Optional: Polishing the edges and/or bottom surface of the recess 6 by laser processes [0131] V Inserting an electrical attachment part 2 in the recess 6, [0132] VI Laminating a laminated pane 1 formed from the inner pane 3 and the outer pane 4 with interposition of the thermoplastic intermediate layer 5.
[0133] If the recess 6 is still accessible after lamination of the laminated pane 1 in step VI (through-going hole or partial recess on the outer side), the electrical attachment part 2 is inserted into the laminated pane after lamination (step V through step VI). If, after lamination of the laminated pane, the recess is fully enclosed thereby and is no longer accessible, the electrical attachment part 2 is inserted into the recess 6 before lamination.
[0134] FIGS. 6a, 6b, 6c, 6d, and 6e depict a plan view, a cross-section, and several detailed views of an embodiment of the laminated pane according to the invention with at least one recess 6 in the form of a through-going hole, in which an electrical attachment part 2 is integrated. FIG. 6a depicts a plan view of the laminated pane 1 comprising an inner pane 3 and an outer pane 4 that are laminated together via a thermoplastic intermediate layer 5. The inner pane 3 has an outer surface IV and an inner surface III. The outer pane has an inner surface II and an outer surface I. The thermoplastic intermediate layer 5 joins the inner surface III of the inner pane 3 and the inner surface II of the outer pane 4. The laminated pane 1 is used as a roof panel of a motor vehicle. The outer pane 4 and the inner pane 3 are made of soda lime glass, with the outer pane 4 tinted gray. The thermoplastic intermediate layer 5 is a polyvinyl butyral film with a thickness of 0.76 mm measured prior to the lamination operation. The laminated pane 1 has a recess 6 in which an electrical attachment part 2 is embedded. The electrical attachment part 2 is a light source in the form of a SMD LED, used for the interior lighting of the vehicle. The recess 6 has a circular through-going hole, to which two angular regions with a partial recess are connected in the form of a sloped inner edge K. The inner side II of the outer pane 4 is equipped with an electrically conductive layer 11. The electrically conductive layer 11 is used for window heating, but simultaneously for electrically contacting the electrical attachment parts 2. For this, laser patterning (not shown) is introduced into the electrically conductive layer 11 to create corresponding current paths for connecting the attachment part 2. FIG. 6b depicts a cross-section through the embodiment of FIG. 6a along the cutting line DD′. The recess 6 is closed on the inner side IV of the inner pane 3 by a cover 9 in the form of a TIR. The lens scatters the light of the SMD LED such that the interior of the vehicle is satisfactorily illuminated. The electrical attachment part 2 is mounted directly on the lens such that the lens and the light source can be removed together from the vehicle-interior side. The electrical attachment part 2 is contacted via a foil-like connection element 10 to the current paths introduced into the electrically conductive layer 11. The foil-like connection element 10 has electrical contacts and a bonding surface on the surface facing the electrically conductive layer 11. The surface of the foil-like connection element 10 facing the light source has a metallic layer via which the electrical contacting with the LED occurs. The LED and foil-like connection element 10 are not connected materially to one another such that the light source can be easily replaced. Direct contact of an electrical attachment part 2 and a foil-like connection element 10 suffices for electrical contacting. Electrical attachment parts, in particular LED light sources, that enable such areal contacting are sufficiently well-known. The arrangement comprising an electrical attachment part 2 and the cover 9 implemented as a lens is reversibly fixed in the recess by fastening elements 12. FIGS. 6c and 6e depict the inner pane 3 with a recess 6 of the laminated pane of FIGS. 6a and 6b in detail. FIG. 6d depicts the cover 9 inserted in the recess 6 in the form of a lens in detail. Fastening elements 12 are molded onto the cover 9 in the form of clip profiles. These are reversibly inserted into the part of the recess 6 that has a sloped inner edge K. FIG. 6e depicts a detailed view of the inner edge K of the recess 6. The circular section of the recess 6, which is implemented in the form of a through-going hole, has an angle of 90° between the inner edge K and the inner side IV of the inner pane 3. The inner side IV is depicted in the detailed view of FIG. 6e as a dashed auxiliary line. In the region of the recess 6, in which the inner edge K is sloped, the inner edge K and the inner side IV have an angle of 45° relative to one another. This section of the recess serves for the precise accommodation of the fastening elements 12. In this manner, the cover 9 including the electronic attachment part 2 can be conveniently and reversibly inserted into the roof panel. Such complex recesses are only achievable via laser methods.
LIST OF REFERENCE CHARACTERS
[0135] (1) laminated pane
[0136] (2) electrical attachment part
[0137] (3) inner pane
[0138] (4) outer pane
[0139] (5) thermoplastic intermediate layer
[0140] (6) recess
[0141] (7) electrical supply line
[0142] (8) patterning
[0143] (9) cover
[0144] (10) foil-like connection element
[0145] (11) electrically conductive layer
[0146] (12) fastening elements
[0147] AA′, BB′, CC′, DD′ section lines
[0148] K inner edge of the recess 6
[0149] α angle between outer side of the pane and inner edge of the recess 6
[0150] I outer side of the outer pane 4
[0151] II inner side of the outer pane 4
[0152] III inner side of the inner pane 3
[0153] IV outer side of the inner pane 3
