Method for producing a thermoplastic combination film

Abstract

A method for producing a thermoplastic combination film suitable for a composite glass pane, wherein the thermoplastic combination film includes at least one defined area, which is provided for a camera window or an HUD (head-up display) region that has a variable wedge angle, the method including providing a first thermoplastic film, producing a second thermoplastic film with a variable wedge angle, wherein the three-dimensional shape of second thermoplastic film is obtained by molding on a mold, and joining together the first thermoplastic film and the second thermoplastic film.

Claims

1. Method for producing a thermoplastic combination film suitable for a composite glass pane, wherein the thermoplastic combination film comprises at least one defined area, which is provided for a camera window or an HUD (head-up display) region that has a variable wedge angle, the method comprising: providing a first thermoplastic film, producing a second thermoplastic film with a variable wedge angle, wherein a three-dimensional shape of the second thermoplastic film is obtained by molding on a mold, and joining together the first thermoplastic film and the second thermoplastic film.

2. The method according to claim 1, wherein the molding on a mold comprises: obtaining a polymer melt, introducing the polymer melt into the mold, releasing the second thermoplastic film from the mold.

3. The method according to claim 1, wherein joining together the first thermoplastic film and the second thermoplastic film and producing the second thermoplastic film are done simultaneously.

4. The method according to claim 1, wherein joining together the first thermoplastic film and the second thermoplastic film comprises placing the second thermoplastic film on the first thermoplastic film, and gluing and/or laser welding and/or cold welding and/or ultrasonic bonding.

5. The method according to claim 1, wherein the first thermoplastic film has a constant thickness.

6. The method according to claim 1, wherein the first thermoplastic film and the second thermoplastic film contain at least one material selected from the group consisting of polyvinyl butyral, ethylene vinyl acetate, polyethylene terephthalate, polyurethane, polypropylene, polyacrylate, polyethylene, polycarbonate, polymethyl methacrylate, polyvinyl chloride, polyacetal resins, casting resins, polyacrylates, fluorinated ethylene propylene copolymers, polyvinyl fluoride, ethylene tetrafluoroethylene copolymers, and copolymers and mixtures thereof.

7. The method according to claim 6, wherein the first thermoplastic film is made substantially of PVB.

8. Head-up display arrangement, comprising a projector for illuminating a head-up display area of a composite glass pane and a composite glass pane equipped with a thermoplastic combination film obtained according to a method of claim 1, wherein, during operation, the projector substantially illuminates the defined area.

9. Camera arrangement, comprising a camera and a composite glass pane at least comprising a first glass layer, a second glass layer, and a thermoplastic combination film obtained according to a method of claim 1, wherein the thermoplastic combination film is arranged between the first glass layer and the second glass layer and wherein the camera is directed at the defined area and records light beams that pass through the composite glass pane.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the present invention are described by way of example with reference to the appended drawings, which depict:

(2) FIG. 1 the basic context of the development of double images in transmittance,

(3) FIG. 2 the basic context of the development of ghost images in reflection,

(4) FIG. 3 an exemplary structure of a composite glass pane with a wedge-shaped intermediate layer,

(5) FIG. 4 a cross-section through a region of a thermoplastic combination film according to the invention,

(6) FIG. 5 a plan view of a composite glass pane according to the invention with a camera window,

(7) FIG. 6 the basic structure of a camera arrangement,

(8) FIG. 7 a plan view of a composite glass pane according to the invention with an HUD region, and

(9) FIG. 8 a schematic representation of a method according to the invention.

(10) FIG. 1 depicts the basic context of the development of double images in transmittance with reference to a beam image. A curved pane 1 is assumed. The curved pane has, at the point of entry of a beam into the curved glass pane 1 a radius of curvature (R+D). Light is now emitted from a light source 3. This light strikes the pane and is refracted in accordance with the known refraction laws at the transition from air to glass on the first boundary surface and from glass to air on the second boundary surface and reaches the eye 2 of an observer. This beam is depicted as a solid line P. From the perspective of the observer, the light source 3 appears to be situated at the location 3. This is depicted as beam P. In addition to this beam P referred to as the primary beam, the beam is, however, only partially refracted on the second gas/air boundary surface in the manner described above; a smaller fraction is reflected on the second boundary surface and is once again reflected on the first boundary surface before the beam now passes through the second boundary surface and reaches the eye 2 of the observer. This beam, the so-called secondary beam is depicted as a dashed line S. From the perspective of the observer, the light source 3 also appears to be situated at the location 3. The angle n enclosed by the primary beam P and the secondary beam S is the so-called double image angle.

(11) In order to address this double image, provision can now be made to provide a wedge angle between the two boundary layers assumed to be substantially parallel in FIG. 1.

(12) According to J. P. Aclocque Doppelbilder als strender optischer Fehler der Windschutzscheibe [Double Images As Interfering Optical Errors in Windshields] in Z. Glastechn. Ber. 193 (1970) pp. 193-198, the double image angle can be calculated as a function of the radius of curvature of the glass pane and the angle of incidence of the light beam according to the following equation:

(13) $=\frac{2d}{R}.Math.\frac{\sin }{\sqrt{n^2-{\sin }^2}},$
where
is the double image angle, n is the index of refraction of the glass, d is the thickness of the glass pane,
R is the radius of curvature of the glass pane at the location of the incident light beam, and is the angle of incidence of the light beam relative to the perpendicular on the tangent to the pane.

(14) In the case of flat glass panes, the double image angle is, according to the following formula

(15) $=2.Math..Math.\frac{\sqrt{n^2-{\sin }^2}}{\cos }$
a function of the wedge angle formed by the glass surfaces.

(16) Thus, by setting the aforementioned formulas equal, the wedge angle necessary for the elimination of the double image can be calculated:

(17) $=\frac{d}{R}.Math.\frac{\cos .Math.\sin }{n^2-{\sin }^2}.$

(18) Usually, this wedge angle is realized in that in composite glass panes 1 a wedge-shaped intermediate layer F is placed between a first glass layer GS.sub.1 and a second glass layer GS.sub.2, see FIG. 3. It can usually be assumed for the sake of simplicity that the index of refraction n is constant, since the difference in the index of refraction of the intermediate layer F and the glass panes GS.sub.1, GS.sub.2 is rather small such that there is hardly any effect due to the small difference.

(19) This idea can be also applied with curved windshields. Usually, for the sake of simplicity, the angle of incidence and the radius of curvature are assumed for a reference eye point, and the wedge angle determined therewith is used for the entire windshield.

(20) In the case of large composite glass panes 1, so-called panorama panes, and/or more highly curved composite glass panes 1, this approach is, however, no longer adequate such that here, usually, a wedge-angle progression variable in the vertical direction must be determined.

(21) Then, it is possible, for example, by pointwise calculation along an imaginary vertical center line of a composite glass pane and possible interpolation, to determine a compensation wedge-angle profile . After determination of the compensation wedge angle profile, a corresponding intermediate layer F can be produced.

(22) With regard to head-up displays, a problem develops which is similar to the phenomenon of double images and is referred to as a ghost image.

(23) FIG. 2 presents the basic context of the development of ghost images in reflection with reference to a beam image. Here, a curved glass pane 1 is assumed. The curved glass pane 1 has a radius of curvature R at the point of entry of a beam into the curved glass pane 1. Light is now emitted from a light source 3, which is representative of a head-up display HUD. This light impinges on the glass pane 1 along the beam R.sub.i from the inside at an angle and is reflected there at the same angle . The reflected beam R.sub.r reaches the eye 2 of an observer. This beam path is depicted as a solid line. From the perspective of the observer, the light source 3 appears to be situated virtually at the location 3, i.e., in front of the glass pane 1. This is depicted as beam R.sub.v. In addition to this first beam, another beam reaches the eye 2 of the observer. This beam R.sub.i likewise originates from the light source 3. However, this beam R.sub.i penetrates, in accordance to the known laws of refraction, into the glass pane 1 on the inner air/glass boundary surface and is reflected on the outer glass/air boundary surface before the beam passes through the inner boundary surface and reaches the eye 2 of the observer as beam R.sub.r. The term inner boundary surface thus refers to the boundary surface that is situated closer to the observer, whereas the term outer boundary surface refers to the boundary surface that is farther away from the observer. This beam path is depicted as a dashed line. From the perspective of the observer, the light source 3 appears to be situated virtually at the location 3, i.e., likewise in front of the glass pane 1. This is depicted as beam R.sub.v.

(24) To address this problem, the wedge angle can now be altered such that the beam R.sub.r reflected on the outer boundary surface and the beam R.sub.r reflected on the inner boundary surface overlap relative to the eye 2 of the observer, i.e., the beam reflected on the outer boundary surface exits at the point of reflection of the beam impinging on the inner boundary surface.

(25) However, if this is done only for a single eye position, the wedge angle determined therefrom can yield non-optimum results. This can be explained, among other things, by the fact that both the body sizes of drivers for whom the HUD displays are primarily intended and the seating position are very different such that there are a large number of possible eye position. This results in the fact that the virtual display is situated in different places depending on the eye position; and, accordingly, there is, for each of these eye positions, a sometimes different value for an optimized wedge angle. In addition, a wedge angle optimized exclusively for ghost images usually results in an overcompensation of double images such that the double images thus caused are again problematic relative to the perception of the observer and/or compliance with regulatory test specifications and/or compliance with customer specifications relative to double images.

(26) Wedge angle profiles that take into account both the different eye positions, i.e., also the compensation of double images in the HUD region are not constant in either the horizontal or the vertical direction. The resultant thickness profiles for the intermediate layer F cannot be produced by simple extrusion processes.

(27) FIG. 4 depicts a region of a thermoplastic combination film F according to the invention in cross-section. The combination film F is made up of two parts: the first thermoplastic film F1 and the second film F2. The first thermoplastic film is made, in the example, of PVB with a constant thickness h1 of 0.76 mm and the second film F2 is also made of PVB; however, the thickness varies within the specified area K, wherein the maximum thickness, h.sub.max of the second thermoplastic film is 0.18 mm. The value h.sub.max is measured at the point at which the second thermoplastic film F2 is the thickest. In the defined area, the wedge angle initially increases slowly in the first border region g1; and, then, in a central region increases according to a previously optimized profile. Following that, the wedge angle decreases slowly again in a second border region g2 in order to make the transition to the first thermoplastic film F1 as little visible as possible. This arrangement with two border regions with a slowly increasing or decreasing wedge angle above and below or to the right and the left relative to an installed window pane is particularly advantageous for minimizing the adverse optical impact at the transition from the first thermoplastic film to the second thermoplastic film.

(28) FIG. 5 depicts a plan view of a composite glass pane according to the invention 1. The composite glass pane is provided as a windshield of a passenger car. The upper edge in the figure borders the roof edge in the vehicle, and the lower edge borders the engine edge. A camera window K is arranged in the upper third of the composite glass pane outside the through-vision area. The windshield preferably has, in the upper edge region, a masking print 9. Masking prints are common for vehicle panes outside the central field of vision to conceal attachment parts or to protect the adhesive with which the vehicle pane is connected to the car body against UV radiation. The masking print typically consists of a black or dark enamel applied and fired in a screen printing process. In the example, the masking print 9 frames the camera window K of the vehicle pane circumferentially to conceal the camera positioned therebehind. The composite glass pane consists of two glass layers, GS1 and GS2, and a thermoplastic combination film F, which is arranged between these glass layers. The glass layers GS1 and GS2 are made of soda lime glass and have a thickness of 2.1 mm. The thermoplastic combination film F is formed as described in FIG. 4. The specified area K forms the camera window.

(29) FIG. 6 depicts a possible camera arrangement 6 consisting of the composite glass pane 1 described and camera 7. The glass layer GS1 of the composite glass pane 1 is directed toward the outside of the vehicle and the glass layer GS2 toward the inside. The camera 7 is arranged in the interior of the vehicle and records the light beams that pass through the composite glass pane 1 from the outside inward. The camera is aimed at the defined area; this means that it is mounted such that the light beams pass through the region with the optimized wedge angle profile. Thus, the double images in transmittance are efficiently reduced. This can, for example, be used successfully in the area of lane assistance systems.

(30) FIG. 7 depicts a plan view of a composite glass pane according to the invention 1 with an HUD region. The HUD region is situated in the defined area in which an optimized wedge angle profile is arranged for preventing ghost images and double images. The HUD region is situated, in the example depicted, on the left side of the windshield in the through-vision region. During production of the composite glass pane 1 from a glass layer GS1, a glass layer GS2, and a thermoplastic combination film F according to the invention, this design can be readily adapted for a right-hand drive vehicle, by placing a second thermoplastic film F2 with an optimized wedge angle profile on the right side.

(31) FIG. 8 depicts, by way of example, a method cycle according to the invention. There in step I, a polymer melt 8 is obtained. In an injection molding operation, the polymer granulated is, for example, heated in a screw extruder under elevated pressure; and then the polymer melt obtained is injected under elevated pressure through a nozzle into the mold 4. Alternatively, the polymer melt 8 is introduced into the mold 4 at atmospheric pressure. The polymer melt 8 solidifies in the mold 4 and assumes the shape of the mold 4 (step II) such that the second thermoplastic film F2 can be released 4 in step III. The mold 4 is preferably coated with Teflon to facilitate the release of the thin second thermoplastic film F2. The first thermoplastic film F1 with a constant thickness is provided. The second thermoplastic film F2 is placed on the first thermoplastic film F1 and welded to the first thermoplastic film F1.

LIST OF REFERENCE CHARACTERS

(32) GS1 glass layer 1, first glass layer, first glass pane GS2 glass layer 2, second glass layer, second glass pane F thermoplastic combination film, wedge-shaped intermediate layer, K defined area F1 first thermoplastic film F2 second thermoplastic film g1 first border region g2 second border region h1 thickness of the first thermoplastic film h.sub.max maximum thickness of the second thermoplastic film 1 glass pane 2 eye 3 light source, HUD projector 4 mold 5 HUD arrangement 6 camera arrangement 7 camera 8 polymer melt 9 masking print