阅读说明：本技术 具有改善的光学性能的汽车用夹层板 (Automobile sandwich panel with improved optical properties ) 是由 马里奥·阿图罗·曼海姆·阿斯塔特 查尔斯·斯蒂芬·弗尔策尔 安德烈斯·费尔南多·萨缅托·桑托斯 于 2018-08-23 设计创作，主要内容包括：在现代汽车行业中,基于摄像头安全系统的使用正在迅速增长。随着行业向着完全自主能力方向的发展,摄像头的数量以及其分辨率都呈现出了增长趋势。与此同时,安装着摄像头的挡风玻璃正在变得越来越大且形状复杂。这就在相机光学领域带来了一些问题。玻璃和塑料层的厚度会有变化,表面失配,表面纹理和玻璃设计的曲率通常在低安装角度被结合在一起,这样做可能会降低相机光学元件的光学清晰度。在压层过程中,当那些层在压力作用下被粘合在一起时这些光学像差将会进一步恶化。本发明的压层板在层压板的侧面的塑料粘合层上采用/应用一个切口,从相机视野角度来看是可取的/更合适的。层压树脂用来填充在两个玻璃层之间切口留下的空隙。(In the modern automotive industry, the use of camera-based security systems is rapidly increasing. As the industry moves toward full independence, the number of cameras and their resolution have shown a growing trend. Meanwhile, the windshield on which the camera is mounted is becoming larger and more complicated in shape. This presents problems in the field of camera optics. The thickness of the glass and plastic layers can vary, surface mismatches, surface textures and curvatures of the glass design are often combined at low mounting angles, which can reduce the optical clarity of the camera optics. These optical aberrations are further exacerbated during lamination when the layers are bonded together under pressure. The laminate panel of the invention makes/applies a cut in the plastic adhesive layer on the side of the laminate, which is desirable/more suitable from a camera view point. The laminating resin is used to fill the void left by the cut between the two glass layers.)

1. A method of producing laminated glass comprising:

providing an outer glass layer, an inner glass layer, and at least one plastic bonding layer between the outer glass layer and the inner glass layer;

making at least one cut-out region in the at least one plastic adhesive layer;

placing an insert of suitable dimensions in the cut-out region of said at least one plastic adhesive layer;

laminating the glass;

injecting a laminating resin into the cut-out region; and

and curing the resin.

2. The method of claim 1, further comprising, between the step of laminating glass and the step of injecting laminating resin, the steps of: the insert is removed from the laminate.

3. The method of claim 2, wherein the insert is provided with at least one lug portion extending to an edge of the glass.

4. The method of claim 3, wherein the insert is configured in a serpentine shape.

5. The method of claim 3, wherein the insert is provided with perforations.

6. The method of claim 1, wherein the insert has a thickness substantially the same as a thickness of the plastic adhesive layer.

7. The method of claim 1, wherein the width of the insert is tapered.

8. The method of claim 1, wherein at least one of the glass layers is cold-bent.

9. The method of claim 1, wherein the laminated glass is annealed or strengthened.

10. A laminated glass produced according to the method of claim 1.

11. The laminated glass according to claim 10, further comprising an infrared reflective coating or an infrared reflective film.

12. The laminated glass of claim 10, wherein at least one of the glass layers is cold-bent.

13. The laminated glass of claim 10, wherein at least one of the glass layers is chemically tempered.

14. The laminated glass of claim 10, wherein at least one of the glass layers has a thickness of less than about 1.6 mm, preferably between about 0.04 mm and about 1.2 mm.

15. A method of producing laminated glass comprising:

providing an outer glass layer, an inner glass layer, and at least one plastic bonding layer between the outer glass layer and the inner glass layer;

Making at least one cut-out region in said at least one plastic adhesive layer;

providing a set of at least two plates sized larger than the cut-out area;

mounting the plate to the opposed glass surfaces with a sealing means;

laminating the glass;

removing the panel from the laminate after lamination;

filling the voids left by the board with laminating resin; and

and curing the resin.

16. A method of producing laminated glass comprising:

providing an outer glass layer, an inner glass layer, and at least one plastic bonding layer between the outer glass layer and the inner glass layer;

making at least one cut-out region in said at least one plastic adhesive layer;

pre-laminating the glass; making an opening in the inner glass layer;

injecting a laminating resin into the cutout region through the opening;

curing the resin; and

and (3) laminating the glass.

17. A method of producing laminated glass comprising:

providing an outer glass layer, an inner glass layer, and at least one plastic bonding layer between the outer glass layer and the inner glass layer;

laminating the glass;

removing at least one cut-out region in the at least one plastic adhesive layer by an ablation process, thereby forming a fill channel extending to the edge of the glass;

Injecting a laminating resin through the channel; and curing the resin.

Technical Field

The present invention relates to the field of automotive laminated glass.

Background

The use of camera-based security systems, which require a wide field of view and a high level of optical clarity, is rapidly increasing. As the industry moves toward full independence, the number of cameras and their resolution have shown a growing trend. Meanwhile, the windshield on which the camera is mounted is becoming larger and more complicated in shape.

The primary cameras all require a higher forward view; it must therefore usually be mounted on the windscreen and located in the region of the wipers. Early initial applications were primarily for night vision. Today, the use of camera-based security systems can provide a wide variety and range of security functions, including: adaptive cruise control systems, obstacle detection, lane departure warning systems and support for automatic operation. Many of these applications require the use of multiple cameras. A high definition and undistorted field of view with minimal double imaging and excellent MTF (modulation transfer function, to measure how well the lens maps the image onto the sensor) is crucial based on whether the camera system can perform as intended. For these systems, it is most critical that the objects can be quickly distinguished, the characters can be captured and edited, the signals can be recognized, and the system can also operate under the condition of low illumination. In addition, as camera resolution increases, the demand for high-definition and undistorted views also increases.

Laminated windshields are made by bonding two annealed sheets of glass together using an interlayer which is a sheet of thermoplastic used to bond the glass layers together. Annealed glass is a glass article that is slowly cooled from the bending temperature during the bending process until the glass transitions into the proper bending range. This process reduces the possibility of residual stress in the glass during bending. When the annealed glass breaks, it will present large fragments with sharp edges. When the laminated glass is broken, the broken glass pieces are bonded together by the plastic layers as are the pieces in a puzzle, thereby helping to ensure the structural integrity of the glass. A vehicle with a broken windshield may still be operated. The plastic adhesive layer 4 also prevents objects from striking the laminate from the outside of the vehicle in the event of a collision; at the same time, it is ensured that the occupant retention can be improved in the event of an accident.

In the optical field, such a laminated structure has a problem. First, the camera needs to look out through at least a third layer of curved glass bonded together with plastic. Secondary reflections from multiple surfaces may result in the creation of ghost images. The curvature of the glass is usually at a low mounting angle, whereby double imaging problems may also occur; thereby further reducing the optical clarity of the field of view.

A further problem may arise due to the varying thickness of the glass and the plastic layers used to bond the two layers of glass together.

Most of the flat glass in the world is manufactured by the float glass production method. This process was first commercialized in the 1950 s. In the float glass production process, raw materials are melted in a large refractory vessel, and the molten glass is then extruded from the vessel into a tin bath, thereby producing float glass. The thickness of the glass is controlled by the speed at which the glass is drawn from the container. The thickness of float glass typically varies +/-50 microns over a short distance due to errors caused by distortion of the draw line. This is a result obtained by using mechanical means to transform the molten glass into a thin ribbon on a flat glass float. As the glass cools and hardens, the ribbon is transferred to a roll.

The thickness of the plastic adhesive layer 4 (intermediate layer) also varies. Automotive sandwiches are made by an extrusion process and thickness tolerances exist to accommodate variations in the process. A smooth surface tends to stick to the glass making it difficult to align the sheet with the corresponding glass and also tends to trap air. To facilitate handling of the plastic sheet and removal of air from the sandwich panel, the plastic surface is typically embossed, adding to the panel the possibility of variation.

Although these variations may themselves cause distortion phenomena, the optical aberrations will be further exacerbated during lamination. During the lamination process, the two sheets of glass are bonded together under pressure and permanently fixed by a plastic adhesive layer. Any surface irregularities or variations in thickness will result in residual stresses being locked into the glass. This is particularly a problem due to the material properties of glass.

Glass is a transparent isotropic substance. The physical properties, such as refractive index, do not depend on their orientation. However, when mechanical stress is applied to the glass, it becomes anisotropic; in the case of glass, its refractive index will change with stress; this phenomenon is known as mechanical birefringence, photoelastic, or stress birefringence. The birefringence induced in the glass is proportional to the stress applied to it.

When the glass is in tension or compression, it will exhibit two polarization dependent indices of refraction; one refractive index for a particular polarization axis and the other refractive index for its vertical axis. For unpolarized light incident in a birefringent material, half of the light will be affected by one refractive index and the other half will be affected by a different refractive index, producing what is commonly referred to as a "ghost image" and distortion. This property is well known in the industry, and the residual stress in glass is measured by using a polarized light source and a polarizing filter.

Another problem with cameras mounted near the top of the windshield is that the tinted sun shade can interfere with the camera system. Thus, on some windshields requiring a camera system, sun shades must be eliminated or provided by other means that are conventionally and economically considered for use. Some alternatives that have been in use include brushing sun shades on the interlayer or the glass itself, as well as mechanical sun shades.

It is desirable to overcome these limitations by providing laminated glass with excellent optical quality and performance properties.

Disclosure of Invention

It is an object of the present invention to provide a laminated glass having excellent optical quality, which is produced by: providing an outer glass layer, an inner glass layer, and at least one plastic bonding layer between the outer glass layer and the inner glass layer; making a cut-out region in said at least one plastic adhesive layer; placing an insert on the at least one plastic adhesive layer sized to fit the cut-out region; laminating the glass; injecting a laminating resin into the incision area; and curing the resin. The insert is made of a material that does not adhere to plastic and does not mark or damage the glass.

It is another object of the present invention to provide a laminated glass having excellent optical quality, which is produced by: providing an outer glass layer, an inner glass layer, and at least one plastic bonding layer between the outer glass layer and the inner glass layer; making at least one cut-out region in the at least one plastic adhesive layer; providing a set of two plates having a size larger than the cut-out area; mounting the plate to the corresponding glass surface by using a sealing means; laminating the glass, removing the sheet from the lamination after the lamination process is complete; filling the gaps left by the board with laminating resin; and curing the resin.

It is still another object of the present invention to provide a laminated glass having excellent optical quality, which is produced by: providing an outer glass layer, an inner glass layer, and at least one plastic bonding layer between the outer glass layer and the inner glass layer; making at least one cut-out region in the at least one plastic bonding layer; pre-laminating the glass; creating an opening in the inner glass layer; injecting a laminating resin into the cutout region through the opening; curing the resin; and laminating the glass.

It is still another object of the present invention to provide a laminated glass having excellent optical quality, which is produced by: providing an outer glass layer, an inner glass layer, and at least one plastic bonding layer between the outer glass layer and the inner glass layer; laminating the glass; removing at least one cut-out region in said at least one plastic adhesive layer by an ablation process to create a fill channel that can extend to the edge of the glass; injecting a laminating resin through the passage; and curing the resin.

The advantages are that:

excellent optical quality:

reducing distortion phenomena caused by glass curvature deviation;

reducing distortion phenomena due to surface mismatch;

reducing distortion phenomena due to birefringence;

reducing distortion phenomena caused by thickness variations of the glass and the intermediate layer;

reducing dual images;

reduction of residual stress;

reduced likelihood of breakage;

cameras supporting higher resolution;

manufacturing using standard procedures and equipment for producing automotive glass;

allowing the use of a pressed sunshade plastic adhesive intermediate layer.

Drawings

Figure 1 is a cross-sectional view of a typical laminate construction.

Fig. 2 is an exploded view of the components of the laminate according to the first embodiment.

Fig. 3A is an isometric view of a windshield according to the first embodiment.

FIG. 3B is a front view of the windshield embodiment depicted in FIG. 3A.

Fig. 4A is a view of a camera optical element fitted with an insert according to a first embodiment.

Fig. 4B is a view of the camera optical element with the insert removed according to the first embodiment.

Fig. 5A is a view of the optical element of the camera fitted with a fill tube according to the first embodiment.

Fig. 5B is a view of the camera optical element with the laminated resin according to the first embodiment.

Fig. 6A is a cross-sectional view of a camera optical element fitted with an insert according to a first embodiment.

Fig. 6B is a cross-sectional view of the camera optical element with the insert removed according to the first embodiment.

Fig. 7A is a cross-sectional view of the optical element of the camera equipped with the filling tube according to the first embodiment.

Fig. 7B is a cross-sectional view of the camera optical element with the laminated resin according to the first embodiment.

Fig. 8 is an exploded view of the components of the laminate according to the second embodiment.

FIG. 9A is an isometric view of an embodiment of a windshield according to a second embodiment.

FIG. 9B is a front view of an embodiment of a windshield according to a second embodiment.

Fig. 10A is a view of a camera optical element fitted with an insert according to a second embodiment.

Fig. 10B is a view of the optical element of the camera according to the second embodiment, with the insert removed.

Fig. 11A is a view of a camera optical element fitted with a fill tube according to a second embodiment.

Fig. 11B is a view of an optical element of a camera with a laminated resin according to a second embodiment.

Fig. 12A is a cross-sectional view of a camera optical element fitted with a fill tube according to a second embodiment.

Fig. 12B is a cross-sectional view of the camera optical element according to the second embodiment with the insert removed.

Fig. 13A is a cross-sectional view of a camera optical element fitted with a fill tube according to a second embodiment.

Fig. 13B is a cross-sectional view of an optical element of a camera equipped with a laminated resin according to a second embodiment.

Fig. 14 is an insert with perforations according to a second embodiment.

Fig. 15 is an insert with perforations and grooves according to a second embodiment.

FIG. 16 is a second embodiment of a perforated, grooved and wire-reinforced insert.

Fig. 17 is an insert molded in accordance with the second embodiment.

Figure 18A is an exploded view of the components of the laminate according to the third embodiment.

Figure 18B is an isometric view of a laminate according to the third embodiment.

Figure 19 is an exploded view of the components of the laminate according to the third embodiment.

Figure 20 is an isometric view of a laminate according to the third embodiment.

Fig. 21 is a detailed view of a plate according to a third embodiment.

FIG. 22A is a cross-sectional view of a void to edge and O-ring-equipped plate according to a third embodiment.

FIG. 22B is a cross-sectional view of a void-to-edge and gasketed plate according to the third embodiment.

FIG. 22C is a cross-sectional view of a void to edge and with an O-ring plate according to a third embodiment.

FIG. 22D is a cross-sectional view of a gasketed plate with voids missing the edges according to the third embodiment.

Fig. 23A is a cross-sectional view showing filling from the glass edge with a tube.

Fig. 23B is a cross-sectional view of filling a glass through-hole with a tube according to the fourth embodiment.

Fig. 24 is a cross-sectional view of PVB laser ablation shown in accordance with a fifth embodiment.

Fig. 25 is an exploded view of components of a laminate having a tapered insert according to a sixth embodiment.

Fig. 26 is a cross-sectional view with a tapered insert according to a sixth embodiment.

Reference numerals:

2 glass

4 plastic tie/adhesive layer

6 Shielding object

8 cuts

12 filling tube

14 insert

15 plate

16 laminating resin

18 gap/clearance

20 perforation

21 sunshade

22 reinforcement

23 gasket/O-ring/gasket

24 holes

26 groove

26 laser

27 laser ablation method

28 lug

30 tapered insert

32 opening in the covering for a camera

101 surface one

102 surface two

103 surface three

104 surface four/fourth surface

201 outer layer

202 inner layer

Detailed Description

In the drawings and discussion, the following description and terminology is used to describe the method of producing laminated glass and the structural features of the laminated glass construction, as shown in FIG. 1. One embodiment of the automotive laminate comprises at least two distinct glass layers separated by a plastic layer. In the embodiment shown in this figure, an outer or exterior glass layer 201 and an inner or interior glass layer 202 are permanently bonded together by a plastic layer 4 (intermediate layer). It should be understood that laminated glass may be comprised of two glass layers and multiple plastic adhesive layers.

In the embodiment shown in fig. 1, the surface of the glass located outside the vehicle is referred to as surface one 101 or first surface. The opposite side of the outer glass layer 201 is surface two 102 or the second surface. The glass surface of the vehicle interior is referred to as surface four 104 or the fourth surface. The inner layer opposite side of glass 202 is surface three 103 or a third surface. Surface two 102 and surface three 103 are bonded together using plastic layer 4.

Thus, the first step of the method of the present invention is to provide an outer glass layer 201, an inner glass layer 202 and at least one plastic bonding layer 4. The plastic adhesive layer 4 has an important function of adhering the main faces of the adjacent layers together. When bonded to another glass layer, the material selected is typically a transparent plastic. For automotive applications, the most commonly used plastic tie layer 4 or interlayer is polyvinyl butyral (PVB). In addition to polyvinyl butyral, ionic polymers, Ethylene Vinyl Acetate (EVA), post-Cure In Place (CIP) liquid laminating resins and Thermoplastic Polyurethanes (TPU), among others, are included. In addition to bonding the glass layers together, the interlayer also has an enhanced function. For example, the invention may include an intermediate layer designed to attenuate sound, provide color tone, absorb or reflect solar energy. Such an intermediate layer consists wholly or partly of a plastic layer which is softer and more flexible than those materials which are generally used or the materials mentioned above.

The laminating resin can function as the plastic adhesive layer. The laminating resin can bond the opposite sides of the glass layers together. Filling the space between the layers with a liquid after bending and lamination can reduce residual stresses in the glass and thus improve the optical clarity of the laminate in this region.