COMPOSITE PANE COMPRISING ELECTRICAL COMPONENT WITH PROTECTIVE COATING

Abstract

A composite pane with at least one integrated electrical component includes an outer pane with an outer face and an inner face, an inner pane with an outer face and an inner face, wherein the inner face of the outer pane and the inner face of the inner pane are connected by a thermoplastic interlayer, wherein the electrical component is integrated between the inner face of the outer pane and the inner face of the inner pane and electrically contacted by at least one conductive track, wherein at least one portion of the exposed surface of the electrical component and optionally at least one portion of the exposed surface of the conductive track is continuously covered by a polymeric protective coating.

Claims

1. A composite pane with at least one integrated electrical component at least comprising an outer pane with an outer face and an inner face, an inner pane with an outer face and an inner face, wherein the inner face of the outer pane and the inner face of the inner pane are connected by a thermoplastic interlayer, wherein the at least one integrated electrical component is integrated between the inner face of the outer pane and the inner face of the inner pane and electrically contacted by at least one conductive track, wherein at least one portion of the exposed surface of the at least one integrated electrical component and optionally also at least one portion of the exposed surface of the at least one conductive track is continuously covered by a polymeric protective coating.

2. The composite pane according to claim 1, wherein the polymeric protective coating comprises amorphous fluoropolymers, fluorinated poly-paraxylylene, non-fluorinated poly-paraxylylene, polyurethane, polyimide, acrylic resin, epoxy resin and/or mixtures or copolymers thereof.

3. The composite pane according to claim 1, wherein a thickness of the polymeric protective coating is between 25 μm and 250 μm.

4. The composite pane according to claim 1, wherein the polymeric protective coating has been applied as a wet coating.

5. The composite pane according to claim 1, wherein the at least one integrated electrical component and/or the at least one conductive track are applied on the inner face of the outer pane or on the inner face of the inner pane.

6. The composite pane according to claim 1, wherein the thermoplastic interlayer comprises at least one lamination film on which the at least one integrated electrical component and/or the at least one conductive track are applied.

7. The composite pane according to claim 1, wherein the thermoplastic interlayer comprises at least one lamination film and at least one carrier foil, wherein the at least one integrated electrical component and/or the at least one conductive track are applied on the carrier foil.

8. The composite pane according to claim 1, wherein the at least one integrated electrical component has a thickness of 70 μm to 700 μm.

9. The composite pane according to claim 1, wherein the at least one electrical component is selected out of the group of LEDs, diodes, resistors, capacitors, transistors, integrated circuits, optoelectronic devices, inductors, sensors, displays, LCD devices, PDLC devices, antenna, piezoelectric elements and crystal elements.

10. The composite pane according to claim 1, wherein the at least one conductive track is implemented as paste, solid ribbon, bus bar, wire and/or thin conductive coating.

11. The composite pane according to claim 1, wherein the conductive tracks contain copper, silver, graphite, graphene, gold, aluminum, tungsten, tin, zinc and/or mixtures or alloys thereof.

12. A method for producing the composite pane according to claim 1, comprising: a) providing an outer pane, an inner pane, at least one lamination film and optionally a carrier foil, wherein at least one conductive track and at least one integrated electrical component are applied on the outer pane, the inner pane, the lamination film or the carrier foil, b) coating at least one portion of the at least one integrated electrical component and optionally at least one portion of the at least one conductive track with a polymeric protective coating, c) arranging a stack comprising at least the outer pane, the lamination film, optionally the carrier foil and the inner pane, wherein the at least one lamination film and the carrier foil can be arranged in any succession, d) joining the outer pane and the inner pane by lamination, wherein a thermoplastic interlayer is formed between the outer pane and the inner pane.

13. The method according to claim 12, wherein the polymeric protective coating is applied by brush coating, selective coating by machine, dispensing, screen printing, ink jet printing, spraying or gluing of adhesive tape.

14. The method according to claim 12, wherein the at least one integrated electrical component and the at least one conductive track are applied on the lamination film or on the carrier foil and wherein step b) is executed before or during step a).

15. A method comprising manufacturing a vehicle glazing with the composite pane according to claim 1.

16. The composite pane according to claim 2, wherein the polymeric protective coating comprises acrylic resin, polyurethanes, epoxy resin and/or mixtures or copolymers thereof.

17. The composite pane according to claim 3, wherein the thickness of the polymeric protective coating is between 25 μm and 100 μm.

18. The composite pane according to claim 1, wherein the thickness of the at least one integrated electrical component is from 100 μm to 500 μm.

19. The method according to claim 13, wherein the polymeric protective coating is applied by spraying.

20. The method according to claim 15, wherein the composite pane is a windshield.

Description

[0058] The invention is explained in detail with reference to drawings and exemplary embodiments. The drawings are schematic representations and not true to scale. The drawings in no way restrict the invention. They depict:

[0059] FIG. 1a a top view of a composite pane 6 according to the invention, wherein the thermoplastic interlayer 3 comprises an LED as electrical component 7,

[0060] FIG. 1b a cross section of the composite pane 6 according to FIG. 1a,

[0061] FIG. 2a a top view of a composite pane 6 according to the invention, wherein the thermoplastic interlayer 3 comprises a touch sensor as electrical component 7 applied on a carrier foil 10,

[0062] FIG. 2b a cross section of the composite pane 6 according to FIG. 2a,

[0063] FIG. 3 a flow chart of a process according to the invention.

[0064] FIG. 1 a depicts a top view of a composite pane 6 according to the invention, wherein the thermoplastic interlayer 3 comprises a light emitting diode (LED) as electrical component 7 and the electrical component 7 is electrically contacted by conductive tracks 8. In FIG. 1b a cross section of the composite pane 6 according to FIG. 1a within section Z along intersection line AA′ is shown. The composite pane 6 is a vehicle windscreen comprising an outer pane 1 with an outer face I and an inner face II and an inner pane 2 with an inner face III and an outer face IV. The inner face II of the outer pane 1 and the inner face III of the inner pane 2 are laminated to each other by a thermoplastic interlayer 3. The thermoplastic interlayer comprises two lamination films 4 out of PVB with a thickness of 0.76 mm each. The outer pane 1 and the inner pane 2 consist of soda lime glass with a thickness of 2.1 mm for the outer pane 1 and 1.6 mm for the inner pane 2. The conductive tracks 8 are printed on a surface of one of the lamination films 4, according to FIG. 1b on the lamination film 4 neighboring the outer pane 1, wherein the surface carrying the conductive tracks is oriented towards the second lamination film 4. The conductive tracks 8 are printed by use of a conductive silver containing paste. The electrical component 7 is attached to the conductive tracks 8 by use of a conductive glue (not shown), wherein the electrical component 7 can be connected to a power supply (not shown) via conductive tracks 8. The exposed surface of the conductive tracks 8 is embedded within the polymeric protective coating 9. The exposed surfaces of the electrical component 7 are as well covered by the polymeric protective coating 9, wherein the surface of the electrical component 7, which is facing towards the inner face III of the inner pane 2 is left out. The polymeric protective coating 9 is applied as spray coating, wherein the uncoated surface of the electrical component 7 is masked during the coating process. As the polymeric protective coating 9 is applied as wet coating, the coating is able to enter the exposed surface of the electrical component 7, which is directed to the underlying lamination film 4 to which the electrical component 7 is attached. The polymeric protective coating 9 comprises an acrylic resin and is applied with a coating thickness of approximately 100 μm.

[0065] FIG. 2a depicts a top view of a composite pane 6 according to the invention, wherein the thermoplastic interlayer 3 comprises a touch sensor as electrical component 7 applied on a carrier foil 10. In FIG. 2b a cross section of the composite pane 6 according to FIG. 2a along the interception line BB′ within sector X is shown. The composite pane 6 is a vehicle windscreen comprising an outer pane 1 with an outer face I and an inner face II and an inner pane 2 with an inner face III and an outer face IV. The inner face II of the outer pane 1 and the inner face III of the inner pane 2 are laminated to each other by a thermoplastic interlayer 3. The thermoplastic interlayer comprises one lamination film 4 out of PVB with a thickness of 0.76 mm. The outer pane 1 and the inner pane 2 consist of soda lime glass with a thickness of 2.1 mm for the outer pane 1 and 1.6 mm forthe inner pane 2. The touch sensor as electrical component 7 is formed by an electrically conductive coating applied on the carrier foil 10. The electrically conductive coating is structured by separation lines, which are free of coating, to form a capacitive area of the sensor and a surrounding area of the sensor. The capacitive area comprises a touch panel, which is intended for operating the touch sensor, and a supplying area, which is intended for connection of the sensor to a sensor control unit by means of a conductor. The conductor paths 8 are formed by the supplying area of the sensor in this case. The separation lines and detailed pattern of the touch sensor is not shown as such sensor layouts are well known within the state of the art. The carrier foil 10 consists of a PET film with a thickness of 50 μm. The electrical component 7 is oriented towards the inner face III of the inner pane 2 as the touch sensor shall be operated form the vehicle interior (outer face IV). The polymeric protective coating 9 is applied on the electrically conductive coating of the electrical component 7 by spray coating, wherein the complete exposed surface of the electrical component 7 as well as a part of the directly adjacent surface of the lamination film 4 is covered by the polymeric protective coating 9. The polymeric protective coating 9 comprises an epoxy resin applied with a coating thickness of 25 μm.

[0066] FIG. 3 shows a flow chart of a process according to the invention comprising the steps:

[0067] I applying an electrical component 7 and/or at least one conductive track 8 on a lamination film 4 or on a carrier foil 10,

[0068] II coating at least parts of the electrical component 7 and optionally also at least parts of the conductive track 8 with a polymeric protective coating 9,

[0069] III accumulating the carrier foil 10 or the lamination film 4, on which the electrical component 7 and/or at least one conductive track 8 are applied, with optional further lamination films 4 to form the foil stack subsequently forming the thermoplastic interlayer 3,

[0070] IV positioning the foil stack of the thermoplastic interlayer 3 onto an outer pane 1 or an inner pane 2 and covering the foil stack with the inner pane 2 or the outer pane 1,

[0071] V autoclaving the arrangement to form a composite pane 6.

REFERENCES

[0072] 1 outer pane [0073] 2 inner pane [0074] 3 thermoplastic interlayer [0075] 4 lamination films [0076] 6 composite pane [0077] 7 electrical component [0078] 8 conductive track [0079] 9 polymeric protective coating [0080] 10 carrier foil [0081] I outer face of outer pane [0082] II inner face of outer pane [0083] III inner face of inner pane [0084] IV outer face of inner pane [0085] AA′, BB′ intersecting lines [0086] Z, X sectors