Abstract
A polymeric vehicle glazing is described, having an outer face and an inner face, with a transparent polymeric component at the outer face and the inner face. An opaque polymeric component is flush mounted at the inner face in at least one section of the transparent polymeric component.
Claims
1.-15. (canceled)
16. A polymeric vehicle glazing, comprising: an outer face and an inner face, the outer face being a same planar face in its entirety; a transparent polymeric component at the outer face and the inner face; an opaque polymeric component flush mounted on the inner face in at least one section of the transparent polymeric component; an interface connecting the transparent polymeric component and the opaque polymeric component and a junction point in which the transparent polymeric component, the opaque polymeric component and the ambient air meet; a first interior face defined as the nearest parallel to the outer face that passes through the transparent polymeric component and the opaque polymeric component; and a second interior face defined as the most distant parallel to the outer face that passes through the transparent polymeric component and the opaque polymeric component, wherein at the junction point, the interface and the second interior face form an angle , wherein is 20 to 100 in direction of the first interior face, wherein the first interior face defines a plane of the interface nearest to the outer face, and wherein within at least one section of the opaque polymeric component, the inner face and the second interior face form an angle R, wherein R is 10 to 100 in direction of the periphery.
17. The polymeric vehicle glazing according to claim 16, wherein the angle that is formed at the junction point is 50 to 90, in direction of the first interior face.
18. The polymeric vehicle glazing according to claim 16, wherein the inner face comprises an adhesive surface which is identical to the second interior face, or parallel to the second interior face and is 0.5 mm to 10 mm above the second interior face.
19. The polymeric vehicle glazing according to claim 16, wherein the inner face comprises at least two electrical contacts and at least one conductive wire and the electrical contacts are located on the opaque polymeric component.
20. The polymeric vehicle glazing according to claim 19, wherein the electrical contacts comprise an upper bus bar and a lower bus bar.
21. The polymeric vehicle glazing according to claim 20, wherein the conductive wires are electrically connected to the upper bus bar and the lower bus bar and the lower bus bar is glued to the opaque polymeric component.
22. The polymeric vehicle glazing according to claim 16, wherein the opaque polymeric component forms a circumferential frame enclosing the transparent polymeric component.
23. The polymeric vehicle glazing according to claim 16, wherein a thickness of the transparent polymeric component is between 1 mm and 20 mm, and a thickness of the opaque polymeric component is between 0.5 mm and 15 mm.
24. The polymeric vehicle glazing according to claim 16, wherein the transparent polymeric component contains polyethylens, polycarbonates, polypropylens, polystyrenes, polybutadienes, polynitriles, polyesters, polyurethanes, polymethylmethacrylates, polyacrylates, polyamides, polyethylenterephthalate, acrylonitrile butadiene styrene, styrene-acrylonitrile, acrylic ester styrene acrylonitrile, acrylonitrile butadiene styrene/polycarbonate, polycarbonate/acrylonitrile butadiene styrene, mixtures and/or copolymers thereof.
25. The polymeric vehicle glazing according to claim 16, wherein the opaque polymeric component contains polyethylenes, polycarbonates, polypropylenes, polystyrenes, polybutadienes, polynitriles, polyesters, polyurethanes, polymethylmethacrylates, polyacrylates, polyamides, polyethylenterephthalate, acrylonitrile butadiene styrene, styrene-acrylonitrile, acrylic ester styrene acrylonitrile, acrylonitrile butadiene styrene/polycarbonate, polycarbonate/acrylonitrile butadiene styrene and/or mixtures or copolymers thereof, and at least one colorant.
26. The polymeric vehicle glazing according to claim 16, wherein the polymeric vehicle glazing is coated with a protective coating comprising at least a polysiloxane, polyacrylate, polymethacrylate and/or a polyurethane, the coating having a thickness between 1 m and 50 m.
27. The polymeric vehicle glazing according to claim 16, wherein the angle R is 20 to 60 in the direction of the periphery.
28. The polymeric vehicle glazing according to claim 18, wherein the adhesive surface is parallel to and 1 mm to 5 mm above the second interior face.
29. The polymeric vehicle glazing according to claim 23, wherein the thickness of the transparent polymeric component is between 2 mm and 8 mm.
30. The polymeric vehicle glazing according to claim 23, wherein the thickness of the transparent polymeric component is between 4 mm and 7 mm.
31. The polymeric vehicle glazing according to claim 23, wherein the thickness of the opaque polymeric component is between 2 mm and 8 mm.
32. The polymeric vehicle glazing according to claim 23, wherein the thickness of the opaque polymeric component is between 3 mm and 5 mm.
33. The polymeric vehicle glazing according to claim 24, wherein the transparent polymeric component contains polycarbonate, polymethylmethacrylate or a combination thereof.
34. The polymeric vehicle glazing according to claim 25, wherein the opaque polymeric component contains polycarbonate, polyethyleneterephthalate, polymethylmethacrylate or a combination thereof.
35. The polymeric vehicle glazing according to claim 25, wherein the opaque polymeric component contains acrylonitrile butadiene styrene/polycarbonate.
36. The polymeric vehicle glazing according to claim 26, wherein the protective coating has a thickness between 2 m and 25 m.
37. A process of manufacturing a polymeric vehicle glazing, comprising: two-component injection molding of a transparent polymeric component and an opaque polymeric component, wherein the opaque polymeric component is flush overmolded onto the transparent polymeric component; applying a protective coating onto the outer face and/or the inner face; applying at least one lower bus bar onto the inner face of the opaque polymeric component; ultrasonically integrating conductive wires onto an inner face of the polymeric vehicle glazing; applying an upper bus bar onto the at least one lower bus bar carrying the conductive wires and establishing an electrical connection of the bus bars with the conductive wires; and obtaining the polymeric vehicle glazing, wherein the polymeric vehicle glazing comprises an outer face and an inner face, the outer face being a same planar face in its entirety, a transparent polymeric component at the outer face and the inner face, an opaque polymeric component flush mounted on the inner face in at least one section of the transparent polymeric component, an interface connecting the transparent polymeric component and the opaque polymeric component and a junction point in which the transparent polymeric component, the opaque polymeric component and the ambient air meet, a first interior face defined as the nearest parallel to the outer face that passes through the transparent polymeric component and the opaque polymeric component, and a second interior face defined as the most distant parallel to the outer face that passes through the transparent polymeric component and the opaque polymeric component, wherein at the junction point the interface and the second interior face form an angle , wherein is 20 to 100 in direction of the first interior face, wherein the first interior face defines a plane of the interface nearest to the outer face, and wherein within at least one section of opaque polymeric component, the inner face and the second interior face form an angle R, wherein R is 10 to 100 in direction of the periphery.
38. The process of manufacturing a polymeric vehicle glazing according to claim 37, wherein the protective coating is applied onto the outer face and the inner face of the polymeric vehicle glazing.
39. A method, comprising: using a polymeric vehicle glazing as automotive glazing, glazing for aviation, glazing for rail vehicles, ship glazing, wherein the polymeric vehicle glazing comprises an outer face and an inner face, the outer face being a same planar face in its entirety, a transparent polymeric component at the outer face and the inner face, an opaque polymeric component flush mounted on the inner face in at least one section of the transparent polymeric component, an interface connecting the transparent polymeric component and the opaque polymeric component and a junction point in which the transparent polymeric component, the opaque polymeric component and the ambient air meet, a first interior face defined as the nearest parallel to the outer face that passes through the transparent polymeric component and the opaque polymeric component, and a second interior face defined as the most distant parallel to the outer face that passes through the transparent polymeric component and the opaque polymeric component, wherein at the junction point the interface and the second interior face form an angle , wherein is 20 to 100 in direction of the first interior face, wherein the first interior face defines a plane of the interface nearest to the outer face, and wherein within at least one section of the opaque polymeric component, the inner face and the second interior face form an angle R, wherein R is 10 to 100 in direction of the periphery.
40. The method according to claim 39, wherein the polymeric vehicle glazing is used in automotives as backlite, sidelite, windshield, lamp cover, or cover for headlamps.
Description
[0044] Further advantages and details of the present invention can be taken from the description of several exemplary embodiments with reference to the drawings.
[0045] FIG. 1a shows the first embodiment of the polymeric vehicle glazing according to the invention wherein the opaque polymeric component is flush mounted onto the transparent polymeric component.
[0046] FIG. 1b shows an enlarged view of the junction region of the polymeric vehicle glazing according to FIG. 1a.
[0047] FIG. 1c shows a first embodiment of the polymeric vehicle glazing according to the invention equipped with conductive wires and an electrical connector.
[0048] FIG. 2 shows another embodiment of the polymeric vehicle glazing according to the invention wherein the opaque polymeric component is flush mounted onto the transparent polymeric component.
[0049] FIG. 3 shows another embodiment of the polymeric vehicle glazing according to the invention wherein the opaque polymeric component is flush mounted onto the transparent polymeric component and the design is optimized for weight reduction.
[0050] FIG. 4 shows another embodiment of the polymeric vehicle glazing according to the invention wherein the opaque polymeric component is flush mounted onto the transparent polymeric component and the design is optimized for weight reduction and demolding.
[0051] FIG. 5a shows another embodiment of the polymeric vehicle glazing according to the invention wherein the opaque polymeric component is flush mounted onto the transparent polymeric component and the design is optimized for glazing with a higher proportion of the opaque polymeric component in the edge region.
[0052] FIG. 5b shows the embodiment of the polymeric vehicle glazing depicted in FIG. 5a, wherein the adhesive surface is identical to the inner face and the angle is =0.
[0053] FIG. 6a shows another embodiment of the polymeric vehicle glazing according to the invention wherein the opaque polymeric component is flush mounted onto the transparent polymeric component and the interface between both components is curved.
[0054] FIG. 6b shows the embodiment of the polymeric vehicle glazing depicted in FIG. 6a, wherein the adhesive surface is identical to the inner face and the angle is =0.
[0055] FIG. 7 shows the embodiment of the polymeric vehicle glazing of FIG. 1a equipped with a protective coating and conductive wires installed in a car body.
[0056] FIG. 8 shows a top view of the polymeric vehicle glazing according to the invention equipped with conductive wires and two electrical connectors.
[0057] FIG. 9 shows a cross-sectional view of the polymeric vehicle glazing according to the invention equipped with conductive wires and two electrical connectors.
[0058] FIG. 10 shows a polymeric vehicle glazing according to the state of the art.
[0059] FIG. 11 shows a flowchart of the process for manufacturing a polymeric vehicle glazing according to the invention.
[0060] FIG. 1a shows a first embodiment of the polymeric vehicle glazing (1) according to the invention shown, wherein the opaque polymeric component (3) is flush mounted onto the transparent polymeric component (2). Only the edge region of the glazing is shown. The outer face (I) of the polymeric vehicle glazing (1) is directed towards the environment, while the inner face (IV) of the glazing points towards the interior of the vehicle. The opaque polymeric component (3) is flush mounted into the transparent polymeric component (2) on the inner face (IV). Flush mounting of the opaque polymeric component (3) generates a planar junction point (9) between the transparent polymeric component (2) and the opaque polymeric component (3). The maximum thickness of the transparent polymeric component (2) is 5.5 mm, whereas it decreases to 3.5 mm in the edge region of the glazing. The opaque polymeric component (3) has got a maximum thickness of 5 mm, which is achieved in the edge region of the glazing and is sunken into the transparent polymeric component (2) by 2 mm in relation to the second interior face (III). The transparent polymeric component (2) and the opaque polymeric component (3) are in direct contact at the interface (V). The line in which the opaque polymeric component (3), the transparent polymeric component (2) and the ambient air are in direct contact is referred to as the junction point (9). A first interior face (ID, which is the nearest parallel to the outer face (I) passing the opaque polymeric component (3) and the transparent polymeric component (2), and a second interior face (III), which is the most distant parallel to the outer face (I) passing the opaque polymeric component (3) and the transparent polymeric component (2), are defined. The interface (V) proceeds between the first interior face (II) and the second interior face (III) over its full length. Initially the interface (V) and the first interior face (II) form an angle of 90 at the junction point (9). Afterwards the slope of the interface (V) changes, wherein the angle .sub.1 between the second interior face (III) and the interface (V) is 35. The transition between these two slopes lies 0.4 mm beneath the surface of the inner face (IV). The initial steep slope of the interface (V) at the junction point (9) followed by a smaller slope leads to the formation of a wall with a height of 0.4 mm. This design avoids an overflowing of the opaque polymeric component (3) during the two-component injection molding process. The interface proceeds towards the first interior face (II) and runs identically to the first interior face (II) subsequently. Hence sharp angles of the interface (V) are avoided, which improves the demolding of the transparent polymeric component (2) and the filling of the opaque polymeric component (3). The angle is defined as the angle between the interface (V) and the second interior face (III) at the junction point (9). Initially the interface (V) deviates from the junction point (9) at an angle of =90 towards the first interior face (II). Afterwards the slope of the interface (V) changes, wherein the angle between the second interior face (III) and the interface (V) after this first transition of slopes is defined as .sub.1. The transition between these two slopes lies 0.4 mm beneath the surface of the inner face (IV). The interface (V) deviates from the second interior face (III) towards the first interior face (II) at an angle of .sub.1=35. The angle in which the inner face (IV) deviates from the second interior face (III) towards the periphery in one section of the opaque polymeric component (3) is =50. Thus the thickness of the opaque polymeric component (3) increases towards the edge of the glazing. The distance between the junction point (9) and this slope of the inner face (IV) is 15 mm. The section of the inner face (IV), which is directly neighboring the edge of the glazing, runs parallel to the second interior face (III) and is defined as the adhesive surface (VI). The adhesive surface (VI) is used to integrate the polymeric vehicle glazing (1) into a vehicle body by applying an adhesive onto the adhesive surface (VI). The adhesive surface (VI) has got a height offset of 3 mm against the second interior face (III).
[0061] FIG. 1b shows an enlarged view of the junction region of the polymeric vehicle glazing according to FIG. 1a. Only the edge region of the glazing is shown. The junction point (9) is defined as the point where the opaque polymeric component (3), the transparent polymeric component (2) and the ambient air meet. The junction point (9) lies at the second interior face (III) and is depicted as a single point in the present cross-sectional view, whereas it forms a circumferential line in top view (see FIG. 8). The interface (V) and the second interior face (III) form an angle at this junction point (9), wherein the interface (V) proceeds towards the first interior face (II). In the present embodiment the angle is =90, whereby the interface (V) runs vertical to the second interior face (III) and forms a small wall before it changes its slope again and forms an angle .sub.1 with the second interior face (Ill) afterwards. The angle .sub.1 is determined by the use of a line parallel to the second interior face (III), which crosses the point in which the slope of the interface (V) changes for the first time. The slope of the interface (V) can change several times in its further progression. In the present embodiment the interface proceeds to the first interior face (II) and runs along the first interior face (II).
[0062] FIG. 1c shows the first embodiment of the polymeric vehicle glazing (1) depicted in FIG. 1a equipped with conductive wires (4) and an electrical connector (8). Only the edge region of the glazing is shown. Flush design of the polymeric vehicle glazing (1) according to the invention enables an easy embedding of the conductive wires (4) on the inner face (IV) by ultrasonic integration as the sonotrode can be driven over a flush surface without hindrance by slopes. The electrical connector (8) is applied on the inner face (IV) in the area of the opaque polymeric component (3), where it is particularly advantageous covered by the opaque polymeric component (3). The conductive wires (4) are embedded into the transparent polymeric component (2) and the opaque polymeric component (3), where they protrude and are connected to the electrical connector (8). Afterwards the ends of the conductive wires (4) are embedded onto the opaque polymeric component (3) again. The electrical connector (8) comprises an upper bus bar (5.1), which is attached to the conductive wires (4) by solder (6), and a lower bus bar (5.2), which is attached to the conductive wires (4) by the pressure of the upper bus bar soldering. The conductive wires (4) are enclosed by the bus bars (5), whereas the lower bus bar (5.2) is attached to the inner face (IV) of the opaque polymeric component (3) by double-faced adhesive tape (7). The inner face (IV) of the transparent polymeric component (IV), the junction point (9) and the inner face (IV) of the opaque polymeric component (3), in which the electrical connector (8) is located, are identical to the second interior face (III). The thickness of the opaque polymeric component (3) increases in the region between the connector (8) and the edge of the glazing, wherein inner face (IV) deviates from the second interior face (III) at an angle of =50 towards the periphery in one section. The distance between the junction point (9) and this slope of the inner face (N) is 15 mm. The section of the inner face (IV), which is directly neighboring the edge of the glazing, runs parallel to the second interior face (III) and is defined as the adhesive surface (VI). The adhesive surface (VI) is used to integrate the polymeric vehicle glazing (1) into a vehicle body by applying an adhesive onto the adhesive surface (VI). The adhesive surface has got a height offset of 3 mm against the second interior face (III).
[0063] FIG. 2 shows another embodiment of the polymeric vehicle glazing (1) according to the invention wherein the opaque polymeric component (3) is flush mounted onto the transparent polymeric component (2). Only the edge region of the glazing is shown. The angle between the interface (V) and the second interior face (III) at the junction point (9) is =35. The slope of the interface (V) changes afterwards, wherein the angle .sub.1 between the interface (V) and the second interior face (III) is .sub.1=0 as the interface (V) runs identical to the first interior face (II) in this section. The inner face (IV) deviates from the second interior face (III) towards the periphery at an angle of =50 in one section of the opaque polymeric component (3). The maximum thickness of the transparent polymeric component (2) is 5.5 mm, whereas it decreases to 3.5 mm in the edge region of the glazing. The opaque polymeric component (3) has got a maximum thickness of 5 mm, which is achieved in the edge region of the glazing and is sunken into the transparent polymeric component (2) by 2 mm in relation to the second interior face (III). The adhesive surface has got a height offset of 3 min against the second interior face (III).
[0064] FIG. 3 shows another embodiment of the polymeric vehicle glazing (1) according to the invention wherein the opaque polymeric component (3) is flush mounted onto the transparent polymeric component (2) and the design is optimized for weight reduction. Only the edge region of the glazing is shown. The angle between the interface (V) and the second interior face (III) at the junction point (9) is =90. The interface changes its slope in its further progression, wherein the transition between the two slopes lies 0.6 mm beneath the surface of the inner face (IV). In this section the interface (V) deviates from the second interior face (III) towards the first interior face (II) at an angle of .sub.1=10. The interface (V) touches the first interior face (II) just in one point and proceeds in the direction of the second interior face (III), forming a rectangle angle between the transparent polymeric component (2) and the opaque polymeric component (3). Hence a recess in the opaque polymeric component (3) is generated, which is filled with the transparent polymeric component (2). The proportion of the transparent polymeric component (3) is thereby increased in relation to the opaque polymeric component (2). As the density of the transparent polymeric component (2) is lower than the density of the opaque polymeric component the weight of the polymeric vehicle glazing (1) can be advantageously reduced. The inner face (IV) deviates from the second interior face (III) towards the periphery at an angle of =50 in one section of the opaque polymeric component (3). The adhesive surface has got a height offset of 3 mm against the second interior face (III).
[0065] FIG. 4 shows another embodiment of the polymeric vehicle glazing according to the invention wherein the opaque polymeric component (3) is flush mounted onto the transparent polymeric component (2) and the design is optimized for weight reduction and demolding. Only the edge region of the glazing is shown. The embodiment of FIG. 3 is optimized further to enhance the demolding. The angle between the interface (V) and the second interior face (III) at the junction point (9) is =90. The interface changes its slope in its further progression, wherein the transition between the two slopes lies 0.6 mm beneath the surface of the inner face (IV). In this section the interface (V) deviates from the second interior face (III) towards the first interior face (II) at an angle of .sub.1=10. The interface (V) touches the first interior face (II) just in one point and proceeds in the direction of the second interior face (III). Hence a recess in the opaque polymeric component (3) is generated, which is filled with the transparent polymeric component (2). The proportion of the transparent polymeric component (3) is thereby increased in relation to the opaque polymeric component (2). As the density of the transparent polymeric component (2) is lower than the density of the opaque polymeric component the weight of the polymeric vehicle glazing (1) can be advantageously reduced. Furthermore a large vertical surface of the interface as depicted in FIG. 3 is avoided, which simplifies the demolding. The inner face (IV) deviates from the second interior face (III) towards the periphery at an angle of =50 in one section of the opaque polymeric component (3). The adhesive surface has got a height offset of 3 mm against the second interior face (III).
[0066] FIG. 5a shows another embodiment of the polymeric vehicle glazing (1) according to the invention wherein the opaque polymeric component (3) is flush mounted onto the transparent polymeric component (2) and the design is optimized for glazing with a higher proportion of the opaque polymeric component (3) in the edge region. Only this edge region of the glazing is shown. The angle between the interface (V) and the second interior face (HI) at the junction point (9) is =90. The interface changes its slope in its further progression, wherein the transition between the two slopes lies 0.6 mm beneath the surface of the inner face (N). In this section the interface (V) deviates from the second interior face (III) towards the first interior face (II) at an angle of .sub.1=10 and runs identical to the first interior face (II) after touching the first interior face. The proportion of the opaque polymeric component (3) is increased in relation to the transparent polymeric component (2) in comparison to the embodiments described so far. Such a design is especially advantageous in view of an optimization of the injection molding process as the cavity is filled out in a better way. The inner face (N) deviates from the second interior face (HI) towards the periphery at an angle of =50 in one section of the opaque polymeric component (3). The adhesive surface has got a height offset of 3 mm against the second interior face (III).
[0067] FIG. 5b shows the embodiment of the polymeric vehicle glazing (1) depicted in FIG. 5a, wherein the adhesive surface (VI) is identical to the inner face (N) and the angle is =0. The flush design of the polymeric vehicle glazing (1) allows an enlargement of the transparent surface as the length of the opaque polymeric component is reduced compared to a glazing according to the state of the art. According to the state of the art the slope of the opaque polymeric component on the inner face (IV) starts right after the end of the interior trim of the car body, in order to completely hide the interior trim by the opaque polymeric component (3). As is 0 in the present embodiment there is no slope on the inner face (IV) of the glazing. Hence the width of this sloped transition surface can be saved, whereby the width of the opaque polymeric component (3) is decreased and the width of the transparent polymeric component (2) is enlarged. Thus the transparent surface of the polymeric vehicle glazing (1) is advantageously enlarged. The width of the transparent surface of the polymeric vehicle glazing (1) according to FIG. 5b can be enlarged by 4 mm compared to a glazing according to the state of the art. Furthermore the package space of the polymeric vehicle glazing (1) is more compact, which is advantageous in car design and in distribution.
[0068] FIG. 6a shows another embodiment of the polymeric vehicle glazing (1) according to the invention wherein the opaque polymeric component (3) is flush mounted onto the transparent polymeric component (2), wherein the interface (V) between the transparent polymeric component (2) and the opaque polymeric component (3) is curved. Only the edge region of the glazing is shown. The angles in which the interface (V) deviates from the second interior face (III) are determined by using tangents. The first tangent defining the angle intersects the junction point (9). Initially the interface (V) deviates from the junction point (9) at an angle of =60 towards the first interior face (II). Afterwards the slope of the interface (V) changes and the following tangent describing the further progression of the interface forms an angle of .sub.1=35 with the second interior face (III). The intersection of those two tangents lies 0.4 mm beneath the surface of the inner face (IV). The angle is also described by using a tangent, which intersects the point where the inner face (N) first deviates from the second interior face. The inner face (N) deviates from the second interior face (III) towards the periphery at an angle of =35.
[0069] FIG. 6b shows the embodiment of the polymeric vehicle glazing (1) depicted in FIG. 6a, wherein the adhesive surface is (VI) identical to the inner face (IV) and the angle is =0. As already described in FIG. 5b the transparent surface of the polymeric vehicle glazing (1) is advantageously enlarged. The width of the transparent surface of the polymeric vehicle glazing (1) according to FIG. 6b can be enlarged by 4 mm compared to a glazing according to the state of the art. Furthermore the packing space of the polymeric vehicle glazing (1) is more compact, which is advantageous in car design and in distribution.
[0070] FIG. 7 shows the embodiment of the polymeric vehicle glazing (1) of FIG. 1a equipped with a protective coating (10) and conductive wires (4) installed in a car body. Only the edge region of the glazing is shown. The protective coating (10) is applied on the inner face (IV) and the outer face (I) of the polymeric vehicle glazing (1). The interior trim (11) is located near the region of the electrical connector (8), where it is advantageously covered by the opaque polymeric component (3). The glazing is installed by gluing the exterior trim (12) to the adhesive surface (VI) with an adhesive (13).
[0071] FIG. 8 shows a top view of the polymeric vehicle glazing (1) according to the invention equipped with conductive wires (4) and two electrical connectors (8). The polymeric vehicle glazing (1) comprises a transparent polymeric component (2) framed by an opaque polymeric component (3), which is flush mounted onto the transparent polymeric component (2). The transparent polymeric component (2), the opaque polymeric component (3) and the ambient air meet at the circumferential junction point (9). The electrical connectors (8) are attached on two opposite sides of the glazing in the region of the opaque polymeric component (3), where they are advantageously hidden by the opaque polymeric component (3). The conductive wires (4) run approximately perpendicular to the electrical connectors (8) and are embedded in the transparent polymeric component (2) and a part of the opaque polymeric component (3). The conductive wires (4) protrude in one region of the opaque polymeric component (3), where they are electrically connected to the electrical connectors (8). The ends of the wires are embedded onto the opaque polymeric component (3) again. To achieve this the sonotrode is lifted up in the region above the lower bus bar (5.2) and lowered onto the surface of the opaque polymeric component (3) again afterwards. The sonotrode draws a semi-circular path to change its direction, whereat the conductive wire (4) is embedded onto the opaque polymeric component (3) along the described path. The upper bus bar (5.1) is attached on top of the lower bus bar (5.2) with conductive wire (4) afterwards.
[0072] FIG. 9 shows a cross-sectional view of the polymeric vehicle glazing (1) according to the invention equipped with conductive wires (4) and two electrical connectors (8). The polymeric vehicle glazing (1) comprises a transparent polymeric component (2) and an opaque polymeric component (3) flush mounted in the edge region of the transparent polymeric component (2). Some examples for flush designs in the edge region of this glazing are depicted in FIGS. 1 to 6. This new design provides a smooth surface for embedding of the conductive wires (4) as there are no slopes in the region on which the embedding should take place. The conductive wires (4) are embedded onto the transparent polymeric component (2) and parts of the opaque polymeric component (3), where they protrude from the opaque material, are electrically connected to the electrical connectors (8) and embedded again afterwards. The electrical connectors are attached to the opaque polymeric component (3) and advantageously hidden by the opaque material after assembly of the glazing to the vehicle body. The opaque polymeric component (3) is equipped with a recess between the electrical connectors (8) and the edge of the glazing. The surface of the opaque polymeric component (3) has got an offset of 3 mm in the edge region compared to the surface carrying the electrical connectors (8). This upper region of the opaque component (3) is used for the adherence of the polymeric vehicle glazing (1) to the vehicle body using an adhesive. The outer surfaces of the transparent polymeric component (2) and the opaque polymeric component (3) are equipped with a protective coating (10).
[0073] FIG. 10 shows a polymeric vehicle glazing (1) according to the state of the art. The opaque polymeric component (3) is not flush mounted into the transparent polymeric component (2), but applied onto the inner face (IV). The lateral edge of the opaque polymeric component (3), which is oriented towards the middle of the glazing, is chamfered. The angle between the inner face (IV) of the opaque polymeric component (3) and the second interior face (III) is =35. Electrical connectors, which shall be hidden by the opaque polymeric component (2), have to be mounted on the adhesive surface (VI), where they hinder the assembly of the glazing to the car body. The embedding of conductive wires has to be accomplished on this slope of the opaque polymeric component (3) to enable a connection to the electrical connector on the upper planar adhesive surface (VI) of the opaque polymeric component (3). However the chamfered edge of the opaque polymeric component (3) exhibits a hindrance for ultrasonic integration of wires as the sonotrode does not reach into the corner and the wires are not embedded satisfactorily. Furthermore the junction (9) between the transparent polymeric component (2) and the opaque polymeric component (3) is not flush, which leads to difficulties during the coating process. At the junction (9) of the glazing the opaque polymeric component (3) and the transparent polymeric component (2) form a corner, in which coating or air bubbles within the coating might accumulate. As this corner lies within the visible region of the glazing the resulting defects lead to rejection of the part. Compared to this the junction of a glazing according to the invention is flush and the corner (if 0) is hidden by the opaque polymeric component.
[0074] FIG. 11 shows a flowchart of the process for manufacturing a polymeric vehicle glazing (1) according to the invention. In a first step the opaque polymeric component (3) is flush-overmolded onto a transparent polymeric component (2) in a two-component injection molding process. The second step of the process comprises the application of a protective coating (10) onto the outer face (I) and/or the inner face (IV) of the polymeric vehicle glazing (1), preferably on the outer face (I) and the inner face (IV). In a third step of the process the lower bus bars (5.2) of the electrical connectors (8) are applied onto the inner face (IV) of the opaque polymeric component (3). The fourth step of the process comprises the ultrasonic integration of conductive wires (4) onto the inner face (IV) of the polymeric vehicle glazing (1). The ultrasonic integration is performed by driving a sonotrode over the inner face (IV) of the polymeric vehicle glazing (1). The conductive wires (4) are embedded onto the transparent polymeric component (2) and parts of the opaque polymeric component (3) and protrude from the polymeric vehicle glazing (1) in the domain of the bus bars (5). In the last step of the process the upper bus bar (5.1) is placed on top of the lower bus bar (5.2) carrying the conductive wires (4) and the electrical connection between the bus bars (5) and the conductive wires (4) is established by application of a conductive adhesive, by soldering or by welding.
REFERENCES
[0075] 1 polymeric vehicle glazing [0076] 2 transparent polymeric component [0077] 3 opaque polymeric component [0078] 4 conductive wires [0079] 5 bus bars [0080] 5.1 upper bus bar [0081] 5.2 lower bus bar [0082] 6 solder [0083] 7 double-faced adhesive tape [0084] 8 electrical connectors [0085] 9 junction point [0086] 10 protective coating [0087] 11 interior trim [0088] 12 exterior trim [0089] 13 adhesive [0090] I outer face [0091] II first interior face [0092] III second interior face [0093] IV inner face [0094] V interface [0095] VI adhesive surface [0096] angle between second interior face and interface at junction point [0097] .sub.1 angle between second interior face and interface [0098] angle between second interior face and inner face [0099] AA cross section
