Laminated glass with an electrically connecting layer and method for producing laminated glass

Abstract

Disclosed herein is a laminated glass (10) having an electrically connectable layer (12) comprising: a first glass substrate (30) and a second glass substrate (36); the electrically connectable layer (12); interlayers (32, 34) positioning the electrically connectable layer (12) between the interlayers (32, 34); and a connecting wire having a first connecting end and a second connecting end and a body portion positioned between the first connecting end and the second connecting end. The first connecting end (26) of the connecting wire is electrically connected to the electrically connectable layer (12) and the body portion of the connecting wire is positioned within the interlayers (32, 34).

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 000,261, filed March 26, 2020, entitled “Laminated Glass with Electrically Connecting Layer”; U.S. Provisional Application No. 63 / 000,243, filed March 26, 2020, entitled “Method for Preparation of Laminated Glass”; and U.S. Provisional Application No. 63 / 000,222, filed March 26, 2020, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure generally relates to laminated glazing having an electrically connected layer and methods for preparing laminated glass having an electrically connectable layer. Background Technology

[0004] Laminated glass is known to be formed from smart glass structures, such as, but not limited to, building or vehicle windows (including interior partitions or skylights), which can selectively switch between an opaque (closed) state for blocking, for example, visible light, infrared and / or ultraviolet energy and / or providing privacy, and a transparent (open) state for allowing light or some light to pass through the structure. Some smart glass structures can also be configured with reverse mode alignment, wherein the smart glass structure is transparent in a default closed state, and opaque in an open state when a voltage is applied.

[0005] The dimming function using, for example (but not limited to), PDLC films can be achieved by applying an electric field to a dimming PDLC material or layer within a glass structure. When the PDLC material is subjected to the applied electric field, discrete formations (such as droplets of liquid crystal dispersed throughout the polymer matrix of the PDLC) become transparent because the long molecular axes of the liquid crystal are aligned with the direction of the electric field in a nematic (parallel) orientation. This parallel orientation provides the direction for light to pass through.

[0006] PDLC materials are typically formed by initiating the polymerization of monomers mixed with liquid crystals, followed by curing of the polymer matrix, which causes the liquid crystals to separate into different domains through the rigid polymer backbone.

[0007] In a typical switchable glass construction, a switchable material (e.g., PDLC, SPD, or electrochromic) can be disposed between two carrier substrates, which can include polymer films such as polyethylene terephthalate (PET) films or the like, which can be coated with a transparent conductive material (e.g., TCO such as indium tin oxide (ITO) or the like) between each polymer film and the switchable material. A PDLC film includes a polymer film, a transparent conductive material, and any interlayer that can be laminated between at least one glass substrate on each side of the PDLC film.

[0008] To control such switchable glass constructions, electrical connections are needed to couple the electrically functional layers with an external power source. In cases where the switchable glass construction is divided into segments for the purpose of controlling based on the segments, each segment needs a power source, and therefore, the electrical connections must be coupled to each electrically functional segment of the separate functional layers. SUMMARY

[0009] Disclosed herein is a laminated glass having an electrically connectable layer, comprising: a first glass substrate and a second glass substrate; an electrically connectable layer; an interlayer, wherein the electrically connectable layer is positioned between the interlayer; at least one connection wire having first and second connection ends and a body portion positioned between the first and second connection ends. The first connection end of each connection wire is electrically connected to the electrically connectable layer, and the body portion of the connection wire is positioned within the interlayer.

[0010] According to embodiments of the present disclosure, the electrically connectable layer can include a switchable film laminated between glass substrates, a light emitting display, a sensor, a light, an antenna, or a heatable coating. The switchable film can be selected from any functional film that can be activated by voltage or signal application, including, for example, liquid crystal films such as polymer dispersed liquid crystal (PDLC) or polymer network liquid crystal (PNLC), nanoparticle films such as suspended particle device (SPD), or electrochromic films.

[0011] The switchable film can be formed with a switchable layer core positioned between first and second electrode layers, where the first electrode layer can be coated on a first film substrate and the second electrode layer can be coated on a second film substrate. Each electrode layer can include at least one bus bar, such that each electrode layer can be connected to a power source. In some embodiments, the first electrode layer can include at least two segments electrically isolated from each other. Each segment can be electrically connected to a connection wire via at least one bus bar on each segment. The second electrode layer can be electrically connected to another connection wire different from the connection wire electrically connected to the segments, or in other words, different from the connection wire connected to the first electrode layer. The segments can have more than one bus bar, including cases where the segments have an aspect ratio of at least 5.

[0012] In some embodiments of the disclosure, the electrically connectable layer can include at least one display, at least two displays, or can include a heatable coating. The second connection end of the connection wire can be connected to a wiring harness. The first connection end of the connection wire can be ring-shaped or zigzag-shaped.

[0013] In some embodiments of the disclosure, the interlayer can surround the electrically connectable layer. The interlayer can include a first interlayer disposed between the first glass substrate and the electrically connectable layer, a surrounding interlayer disposed around the edges of the electrically connectable layer, and a second interlayer disposed between the second glass substrate and the electrically connectable layer.

[0014] In some embodiments of the disclosure, the body portion of the connection wire can be insulated. The first connection end can be attached to the electrically connectable layer by an adhesive layer, which can include a conductive adhesive. The adhesive layer can include an adhesive tape. The adhesive tape can be a copper tape having an adhesive on at least one side of the copper tape. In some embodiments, the adhesive tape can be double-sided such that it includes an adhesive on opposite sides of the tape.

[0015] In another aspect of the disclosure, a method of making a laminated glass is provided, including the steps of: placing at least one connection wire in a first interlayer, wherein each of the at least one connection wire includes a first connection end, a body portion, and a second connection end, wherein placing the at least one connection wire includes embedding the body portion of the connection wire in the first interlayer; placing an electrically connectable layer over the first interlayer such that at least one busbar on the electrically connectable layer overlaps the first connection end of the at least one connection wire, and placing a surrounding interlayer over the electrically connectable layer over the first interlayer, wherein the body portion of the at least one connection wire is positioned between the first interlayer and the surrounding interlayer; placing a second interlayer over the electrically connectable layer and the surrounding interlayer to provide an interlayer stack; placing the interlayer stack between a first glass substrate and a second glass substrate to provide a lamination stack; and laminating the lamination stack to provide the laminated glass.

[0016] The electrically connectable layer can be placed before or after placing the surrounding interlayer. The first connection end of the connection wire can be ring-shaped or zigzag-shaped. The electrically connectable layer can include at least two electrically isolated portions. Each electrically isolated portion can include at least one busbar that overlaps the first connection end of the at least one connection wire.

[0017] In some embodiments, the electrically connectable layer can be a light modulating film. The light modulating film can include bus bars folded around the edges of the light modulating film. An adhesive layer can be placed on the first interlayer prior to placing the at least one connecting wire, wherein the first connecting end is at least partially aligned with the adhesive layer. The adhesive layer can include an adhesive tape, which can include a copper tape having an adhesive on at least one side of the copper tape. The adhesive tape can include a double-sided adhesive tape having an adhesive on opposite sides of the copper tape. The adhesive layer can include a conductive adhesive.

[0018] In yet another aspect of the disclosure, a method of making a laminated glass is provided, comprising the steps of: placing an electrically connectable layer over a wrap interlayer and having at least one bus bar, such that the electrically connectable layer fits within the wrap interlayer; placing at least one connecting wire over the wrap interlayer and the electrically connectable layer, wherein each connecting wire includes a first connecting end, a body portion, and a second connecting end, wherein the first connecting end of each connecting wire overlaps one of the at least one bus bar, and wherein the body portion of each connecting wire is embedded in the wrap interlayer; placing a second interlayer over the electrically connectable layer and the wrap interlayer to provide an interlayer stack; placing the interlayer stack between a first glass substrate and a second glass substrate to provide a lamination stack; and laminating the lamination stack to provide a laminated glass.

[0019] The electrically connectable layer can be placed before or after placing the wrap interlayer. The first connecting end of the connecting wire can be in a loop or a zigzag shape. The electrically connectable layer can include at least two electrically isolated portions. Each electrically isolated portion can include at least one bus bar that overlaps at least one of the first connecting ends of the connecting wire.

[0020] In some embodiments, the electrically connectable layer is a light modulating film. The light modulating film can include bus bars folded around the edges of the light modulating film. In some further embodiments, an adhesive layer can be at least partially placed over the first connecting end on the at least one bus bar prior to placing the third interlayer after placing the at least one connecting wire. The adhesive layer can include an adhesive tape. The adhesive tape can include a copper tape having an adhesive on at least one side of the copper tape. The adhesive layer can include a conductive adhesive. BRIEF DESCRIPTION OF DRAWINGS

[0021] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more aspects of the disclosure and together with the detailed description

[0022] Figure 1 is a schematic plan view showing a laminated glass according to an embodiment of the disclosure;

[0023] Figure 2is an enlarged plan view showing a portion of the laminated glass according to an embodiment of the present disclosure;

[0024] Figure 3 is a perspective cross-sectional view showing a busbar region of the laminated glass according to an embodiment of the present disclosure;

[0025] Figure 4 is a process cross-sectional view showing a step of providing an adhesive layer on the interlayer according to an embodiment of the present disclosure;

[0026] Figure 5 is a process plan view showing a step of providing an adhesive layer on the interlayer as shown in Figure 4

[0027] Figure 6 is a process cross-sectional view showing a step of placing a connecting wire on the adhesive layer and the interlayer according to an embodiment of the present disclosure;

[0028] Figure 7 is a process plan view showing a step of placing a connecting wire on the adhesive layer and the interlayer as shown in Figure 6

[0029] Figure 8 is a process cross-sectional view showing a step of placing an electrically connectable layer on the interlayer according to an embodiment of the present disclosure;

[0030] Figure 9 is a process plan view showing a step of placing an electrically connectable layer on the interlayer as shown in Figure 8

[0031] Figure 10 is a process cross-sectional view showing a step of placing a wraparound interlayer on the interlayer according to an embodiment of the present disclosure;

[0032] Figure 11 is a process plan view showing a step of placing a wraparound interlayer on the interlayer as shown in Figure 10

[0033] Figure 12 is a process cross-sectional view showing a step of placing a second interlayer on the interlayer and the electrically connectable layer according to an embodiment of the present disclosure;

[0034] Figure 13 is a process plan view showing a step of placing a second interlayer on the interlayer and the electrically connectable layer as shown in Figure 12

[0035] Figure 14 is a process cross-sectional view showing a step of placing a laminated stack as shown in Figure 12 ​​​​​​

[0036] Figure 15 is a process plan view illustrating a step of placing a sandwich stack as shown in Figure 16

[0037] Figure 16 is a process sectional view illustrating a step of placing a wraparound interlayer on an interlayer according to another embodiment of the present disclosure;

[0038] Figure 17 is a process plan view illustrating a step of placing a wraparound interlayer on an interlayer as shown in Figure 16

[0039] Figure 18 is a process sectional view illustrating a step of placing an electrically connectable layer having bus bars on an interlayer according to an embodiment of the present disclosure;

[0040] Figure 19 is a process plan view illustrating a step of placing an electrically connectable layer having bus bars on an interlayer as shown in Figure 18

[0041] Figure 20 is a process sectional view illustrating a step of placing a connecting wire on an electrically connectable layer and an interlayer according to an embodiment of the present disclosure;

[0042] Figure 21 is a process plan view illustrating a step of placing a connecting wire on an electrically connectable layer and an interlayer as shown in Figure 20

[0043] Figure 22 is a process sectional view illustrating a step of placing a second interlayer on a wraparound interlayer and an electrically connectable layer according to an embodiment of the present disclosure; and

[0044] Figure 23 is a process sectional view illustrating a step of placing a sandwich stack as shown in Figure 22 DETAILED DESCRIPTION

[0045] In the following description, for the purposes of explanation, specific details are set forth in order to facilitate a thorough understanding of one or more aspects of the disclosure. Nevertheless, it can be apparent to those skilled in the art that many of the aspects described below can be practiced without the specific details.

[0046] ​​​​​Laminated glass can include first and second glass substrates laminated together with a layer of interlayer material. In particular, the interlayer can be a polymeric adhesive such as polyvinyl butyral (PVB), ethylene vinyl acetate (EVA), or ionomer, among others. Laminated glass can also include an electrically connectable layer. The electrically connectable layer can include, for example, a light modulating film, a light emitting display, a heatable layer, an antenna, a sensor, or a lighting device laminated between glass substrates. The light modulating film can include, for example, a liquid crystal film such as a polymer dispersed liquid crystal (PDLC) or a polymer network liquid crystal (PNLC), a nanoparticle film such as a suspended particle device (SPD), or an electrochromic film. In a typical light modulating film, a light modulating layer core including a light modulating material (e.g., liquid crystals of PDLC or PNLC, suspended particle material of SPD, or electrochromic material) can be disposed between two polymer films such as polyethylene terephthalate (PET) films, which can be coated with a transparent conductive material (e.g., a TCO such as indium tin oxide (ITO)) between each polymer film and the light modulating material. The light modulating film includes the polymer films, the transparent conductive material, the light modulating material, and any interlayer that can be laminated between a pair of glass substrates. The transparent conductive material can function as an electrode in the light modulating film and can have independent electrical connections. The electrically connectable layer can be formed as one film that is incorporated into the glass structure. In some embodiments, the electrically connectable layer can be divided into multiple segments that are electrically isolated from one another and each of which requires an electrical connection. When such an electrically connectable layer with multiple segments is used for a light modulating sunroof of a vehicle, the driver or passenger can control the transparency of each segment to make some segments fully transparent while the remaining segments are darkened or blocked from light.

[0047] Laminated glass can include a first interlayer between the first glass substrate and the electrically connectable layer and a second interlayer between the second glass substrate and the electrically connectable layer. It can be preferable that the electrically connectable layer does not reach the edge of the laminated glass. For example, some electrically connectable layers can be subject to corrosion if exposed to certain external environments that include moisture. The electrically connectable layer can include a connectable coating on a substrate, and the edge of the substrate can extend farther than the edge of the connectable coating. In the case where the electrically connectable layer is a film laminated within the glass, the film can not extend to the edge of the glass. In the case where there is no electrically connectable layer around the perimeter of the glass, there can be a thickness variation around the edge of the electrically connectable layer within the laminated glass. To compensate for the resulting variation in glass thickness, another interlayer, or a wraparound interlayer, can be disposed between the first and second interlayers and can wrap around the electrically connectable layer. The wraparound interlayer can be formed with an opening in which the electrically connectable layer can fit.

[0048] During lamination, the lamination stack including the glass substrates, interlayers, and any materials to be laminated between the glass substrates are degassed and autoclaved. The degassing process can include removing air from between the stacked layers to eliminate air pockets in the laminated glass. In some laminated glasses, the inclusion of materials within the glass can complicate the degassing process. For example, connecting materials such as copper tape can impede the degassing process. Copper tape can be used in typical glasses to connect an electrically connectable layer to an external power source. The copper tape can extend from the electrically connectable layer through the glass, through the glass perimeter to a location where the tape can be connected to the external power source. The size and location of the copper tape can make degassing difficult, where the bus bar can block air from escaping to the edge of the lamination stack. For example, the copper tape can be attached to an interlayer such that air cannot pass through the copper tape and the interlayer, which can create a barrier to removing some of the air from the lamination stack, including situations where the air can be blocked between pieces of copper tape. In some glasses, the copper tape extending around the glass perimeter can be aligned with an opaque print such that the tape is not visible to an observer. The opaque print can extend around the glass perimeter and can have a width that covers the bus bar and the copper tape. The required area for the connection between the bus bar and the power source can depend on how large the connection, such as the copper tape, is, which can be related to the required area of the opaque print. In the art, it can be desirable to provide an electrical connection around the glass perimeter with reduced material.

[0049] The electrically connectable layer can be connected to a power source that can supply power to the material within the glass via bus bars. Multiple bus bars can be used with the electrically connectable layer. For example, a heatable coating can have at least two bus bars. In some embodiments, a switchable film can have multiple electrodes, each of which requires at least one bus bar. In some electrically connectable layers, multiple bus bars can be used to provide a uniform electric field. In cases where the electrically connectable layer includes multiple electrically isolated sections, each electrically isolated section can include at least one bus bar for connection to a power source. In some embodiments with a switchable film, in cases where an electrically isolated section has an aspect ratio of at least 5, the electrically isolated section can preferably have at least two bus bars. In cases where a section has multiple bus bars, the bus bars can preferably be positioned on opposite sides of the electrically isolated section to ensure uniform switching of the electrically isolated section. The electrically isolated sections can be physically separated in the electrically connectable layer. For example, an electrically heatable coating can include deletions that isolate sections of the coating from one another, or a light emitting display can be provided in the form of multiple components that are physically isolated from one another. In cases where the electrically connectable material is deleted, any appropriate deletion method can be used, such as laser deletion or mechanical deletion, among others. A switchable film can include a switchable layer core between electrode layers coated on a film substrate. The electrode layers can be connected to a power source to supply power to the switchable film, respectively. Electrically isolated sections of the switchable film can be formed by deletions in one or both electrode layers of the sections forming the layers. Depending on the desired segmentation, one of the electrode layers can remain intact in a segmented switchable film. Sections of the electrically connectable layer can be connected so as to be electrically controlled together or independently.

[0050] Typically, the bus bars can include a bus bar material such as a silver-containing or tin-containing material. In some glasses, a copper tape can be positioned over the bus bar material to provide a flat bus bar surface, which can be preferred for providing an electrical connection. In cases where the electrically connectable layer is segmented with isolated sections, multiple bus bars can be required so that each segment of the layer can be electrically connected. Each electrically isolated section can include at least one independent bus bar. As the number of bus bars required increases, the amount of material required for the bus bars and connections increases, which can increase the impediment to outgassing.

[0051] The present disclosure includes embodiments of laminated glass having reduced presence of connectors for electrically connectable layers within the laminated glass. In particular, laminated glass can be provided having electrically connectable layers connected to a power source via wire-based connections. The wires can include a first connection end and a second connection end separated by a body portion. The first connection end can be electrically connected to a bus bar on the electrically connectable layer, and the second connection end can be connected to a connector or harness extending out of the glass so that it can be connected to a power source. The harness within the glass can be connected to a connector that can extend out of the glass. The body portion of the wire can be located within the interlayer material. Preferably, the body portion of the wire can be positioned around the electrically connectable layer.

[0052] The electrically connectable layer within the laminated glass can include bus bars for connection to a power source. Connection wires can be used to connect the bus bars to the power source and provide electrical connection to the electrically connectable layer. The first connection end of the wire can be aligned with the bus bar and can be shaped to ensure proper connection between the bus bar and the connection wire. For example, the first connection end can be shaped to have a loop or be jagged to increase the surface area of the bus bar that is aligned with the connection wire. Each bus bar can be connected with one or more connection wires. It can be preferable that the first connection end does not overlap with the electrically connectable material of the electrically connectable layer other than through the bus bar to avoid interference in the electrical circuit. Thus, it can be preferable to position the bus bar along or near an edge of the electrically connectable layer to help position the connection wire.

[0053] It can be preferable to mechanically attach the first connection end to the bus bar to ensure that they do not separate during the lamination process and maintain electrical contact between the connection wire and the bus bar and the electrically connectable layer. In some embodiments, the first connection end of the wire can be soldered to the bus bar. In certain embodiments, the first connection end of the wire can be positioned on the bus bar and covered with an adhesive, such as an adhesive copper tape. The copper tape can include an adhesive facing the first connection end, which can include a conductive adhesive. In some further embodiments, the copper tape can be double-sided with adhesive on opposite sides of the tape. Where the copper tape has two adhesive surfaces, the surface facing away from the first connection end can be non-conductive, and the adhesive facing the first connection end can preferably be a conductive adhesive.

[0054] The body portions of the connecting wires can extend through the interlayer outside the edge of the electrically connectable layer. The body portions of the connecting wires can be embedded between the interlayers and can be positioned such that the body portions are isolated from one another. The body portions of the connecting wires can be insulated. In some embodiments, the insulating material can include, for example, a resin coating, which can include a base coating and a colored outer coating. The coating can not extend to the first or second connecting ends of each connecting wire. The insulation around the body portions of the wires can prevent interaction between the connecting wires and the interlayers, including plasticizers in the interlayers. The body portions of the connecting wires can be positioned in any desired shape, including the shape of the edge of the glass substrate or the electrically connectable layer of glass. In some embodiments, the body portions can extend along the edge of the electrically connectable layer, which can include around the corners of the electrically connectable layer. Where the glass includes more than one connecting wire, the wires can have the same or different shapes. The wires can be positioned between the interlayers in a manner that does not overlap one another.

[0055] The body portions of the connecting wires can extend toward the edge of the laminated glass, where the second connecting end of the connecting wire can be attached to a wire harness, which can consolidate the connecting wires to a single connecting element for connection to a power source. In particular, the second connecting end can be connected to a wire harness within the laminated glass such that one connector from the wire harness extends out of the laminated glass for connection to a power source.

[0056] The connecting wires can be any suitable material, such as copper, aluminum, silver, gold, tungsten, or any other electrically conductive metal or alloy to provide sufficient power from the power source to the electrically connectable layer. The connecting wires can include copper wire having an appropriate thickness to power the electrically connectable layer. For example, the diameter of the connecting wires can be 0.25 mm or less, preferably 0.15 mm or less. The amount of power required can depend on the type of electrically connectable layer. For example, a dimmable film can require less power than a heatable coating. Thicker wires or multiple wires can be used to provide more power than a relatively thin wire. The diameter of the connecting wires can be determined to provide an appropriate current density in the wires. For example, where the wires are copper, the current density can preferably be 15 A / mm 2 more preferably 6 A / mm 2 even more preferably 4 A / mm 2 or less. The appropriate current density can depend on the wire material used. In some embodiments, bare wires without additional insulating material can be used for the connecting wires, as the connecting wires can be completely covered except for the electrical contact portions and insulated by the interlayers after the autoclaving process. In some other embodiments, the body portions of the connecting wires can be insulated.

[0057] The use of connecting wires is advantageous for the degassing process during lamination. In cases where copper tape can block the air passage during the degassing process and can also reduce the productivity of the degassing process, connecting wires are desirable for the degassing process as air can easily bypass the wires, making the degassing process faster and more efficient.

[0058] In cases where the electrically connectable layer includes more than one connecting wire, the wires can be attached to a power source or controller in parallel or in series, and the connecting wires can be powered together or separately. In some cases, it can be desirable to power specific portions of the connectable layer while not powering other portions, while in other cases it can be preferable to power the electrically connectable layer uniformly.

[0059] In certain embodiments disclosed herein, the electrically connectable layer can include a light modulating film. As described above, a segmented light modulating film can include at least n+1 bus bars, where n is equal to the number of segments in the light modulating film. The segmented electrode layer can include at least one bus bar in each segment or portion, while the unsegmented electrode layer can include a bus bar. Each bus bar can include a surface for connection to a connecting wire, and each bus bar can have at least one connecting wire. In cases where the light modulating film includes two electrode layers, each connecting wire can be aligned with only one of the electrode layers. For the segmented electrode layer, the connecting wires can be connected to one segment of the electrode layer without contacting other segments.

[0060] Some embodiments can include a light emitting display as the electrically connectable layer. The light emitting display can include, for example, a substrate layer with a coating thereon that can emit light under electrical power. Such a display can include one or more independent laminates in the laminated glass. For example, independent displays can be used in the glass to provide more than one display option and location. The displays can share information inside and / or outside of a vehicle, including providing information such as vehicle movement or occupancy to pedestrians. The laminated display can need to be electrically connected to a power source in order to emit light. The connecting wires as discussed herein can be used to connect the light emitting display to a power source via the bus bars on the light emitting display.

[0061] Figures 1 to 3 A laminated glass with an electrically connectable layer therein is shown. As shown Figure 1 The electrically connectable layer 12 can be formed in a rectangular shape with four rounded corners, and can be encased by interlayers 14, which can be made of polyvinyl butyral resin (PVB) layers. The electrically connectable layer 12 can have any shape in the laminated glass 10. The interlayers 14 and the electrically connectable layer 12 are sandwiched by a pair of glass substrates (not shown in Figure 1 The laminated glass 10 can also include an opaque layer on a portion of the glass, which is not shown in Figure 1 ​

[0062] In particular, the illustrated electrically connectable layer 12 can be a light control film having two electrodes, including a segmented electrode having isolated segments 16a-16g. Segments 16a-16g each have bus bars 20a-20g, and bus bars 20a-20g are shown connected to connection wires 22a-22g, respectively. In some embodiments, one segment can have more than one bus bar. Electrically connectable layer 12 has a common bus bar 18 that is electrically connected to a non-segmented electrode in electrically connectable layer 12. In Figure 1 In the illustrated embodiment, segments 16a-16g are divided by cutouts in the electrode layer that extend parallel to the shorter edges of electrically connectable layer 12, but the segments can be formed in other locations, such as locations where the cutouts extend perpendicular to the shorter edges of electrically connectable layer 12. In variations, the segments can have different sizes from one another. For example, a central segment can be formed in a larger size than the other segments.

[0063] Bus bars 20a-20g and common bus bar 18 are made of a metallic material, bus bars 20a-20g are electrically connected to first connection ends of connection wires 22a-22g, and common bus bar 18 is connected to connection wire 22h. Each of connection wires 22a-22h includes an insulated copper wire. The first and second connection ends of each of connection wires 22a-22h can be free of insulation that can extend over a main portion of connection wires 22a-22h. The first connection ends of wire connections 22a-22h can be positioned to have a coiled or looped shape to obtain a wider contact area between bus bars 20a-20g, 18 and connection wires 22a-22h. Figure 2 Electrically connectable layer 12 is shown with bus bar 20a and first connection end 26 of connection wire 22a. The illustrated construction can be the same at other bus bars 20b-20g, 18 on electrically connectable layer 12. As shown, first connection end 26 of connection wire 22a can be provided in a looped or coiled shape, which can increase the surface area of connection to underlying bus bar 20a. In some embodiments, first connection end 26 of connection wire 22a can be soldered to bus bar 20a. In some other embodiments, an adhesive layer 38, such as a copper tape having adhesive thereon, can be positioned on the other side of first connection end 26. A main portion of connection wire 22a can extend between interlayers 14 around a glass perimeter of electrically connectable layer 12 to an area where it can be connected to a power source. Second connection ends of connection wires 22a-22g, 22h are connected to a wire harness 24, which can be connected to a power source and a controller for controlling electrically connectable layer 12. A wire harness connector (not shown) can be provided to extend from wire harness 24 outside of an edge of the glass substrate.

[0064] Figure 3A three-dimensional cross-sectional view is shown, illustrating a laminated glass 10 in which a dimming film is used as part of an electrically connectable layer 12. Figure 3 The electrically connectable layer 12 shown may include: a dimming layer core 44 comprising a dimming material; two electrode layers 42 and 46 disposed on opposite sides of the dimming layer core 44 and having busbars; and a first film substrate 40 and a second film substrate 48, which may be made of a resin such as polyethylene terephthalate film. The electrode layers 42 and 46 may be formed on the first film substrate 40 and the second film substrate 48. The electrically connectable layer 12 having the dimming layer core 44, electrode layers 42 and 46, and the first film substrate 40 and the second film substrate 48 may be formed as a single film, and the layers of the film may be cut to expose the surfaces of the electrode layers 42 and 46 for use in the electrically connectable layer 12.

[0065] Figure 3 The electrically connectable layer 12 is positioned between interlayers 32 and 34, which are also positioned between the first glass substrate 30 and the second glass substrate 36. As is known in the art, the first glass substrate 30 and the second glass substrate 36 can be soda-lime silicate glass, and the interlayers 32 and 34 can be polyvinyl butyral resin. The interlayers 32 and 34 can also insulate the connecting wires 22a to 22h, and an additional wrapping interlayer can be provided around the electrically connectable layer 12 to prevent thickness variations at the edges of the electrically connectable layer 12. As described below, this additional wrapping interlayer can be provided with openings for assembling the electrically connectable layer 12 therein.

[0066] During assembly, busbars 20a to 20g and the common busbar 18 can be positioned at or near the respective edges of the electrically connectable layer 12. To ensure electrical contact and prevent any short circuits, busbars 20a to 20g and the common busbar 18 can be configured to have a space between busbars 18, 20a to 20g and the opposing electrode layers 42, 46. This space can be filled by interlayers within the laminated glass.

[0067] exist Figure 1 In this configuration, busbars 20a to 20g are disposed on one side of the electrically connectable layer 12. However, in some embodiments, some of the busbars 20a to 20g may be disposed on each side of the electrically connectable layer 12 to divide the number of busbars between sides. For example, if seven sections are configured, three busbars may be disposed on the right side and four busbars may be disposed on the left side. Furthermore, if a section has more than one busbar, the busbars may preferably be positioned on opposite sides of that section.

[0068] Reference Figures 4 to 15 The method for manufacturing laminated glass as described above is explained in detail. In this method, connecting wires can be provided before positioning the wrapping interlayer.

[0069] As shown in Figure 4 and Figure 5 An adhesive layer 38 can be provided on the first interlayer 32 at the location where the first connecting end 26 of the connecting wire is to be provided. The first interlayer 32 can be polyvinyl butyral resin (PVB), ethylene vinyl acetate (EVA), or ionomer as known in the art. The proper positioning of the bus bar 18, 20a-20g and connecting wires 22a-22h can depend on the shape and size of the electrically connectable layer 12 and the laminated glass 10. The adhesive layer 38 can be preferably made of a conductive material such as silver paste or carbon containing adhesive, and the adhesive layer 38 itself can be made of a conductive tape such as a copper tape that can include a conductive paste, etc. The adhesive layer 38 can ensure contact between the bus bar and the connecting wire prior to lamination and maintain the position of the bus bar at the boundary of the electrically connectable layer 12. The adhesive layer 38 can secure the connecting wire to the bus bar to provide electrical contact with the electrode 42 even when the interlayer is soft during the degassing and autoclaving process, and contact the connecting wire 22h on the same side of the electrically connectable layer 12 as the bus bar 20a-20g that contact the connecting wires 22a-22g, as shown in Figure 8 The common bus bar 18 can include an extension to provide suitable material to fold around the edge of the electrically connectable layer 12. For example, the bus bar 18 can include a first bus bar material that can include a conductive material as described above, and a conductive tape extension for folding around the electrically connectable layer 12. The conductive tape can include a conductive adhesive for electrical connection to the first bus bar material. The connecting wire 22h can be connected at the folded portion of the bus bar 18.

[0070] As described above, the light modulating layer core 44 can be made of a light modulating material, encased by two electrode layers 42, 46 that are electrically connected to the bus bar. The electrode layers 42, 46 can be made of ITO film or other transparent conductive film. The first film substrate 40 and the second film substrate 48 can be made of a resin such as polyethylene terephthalate film. The electrically connectable layer 12 can be segmented by dividing the second electrode layer 46 into electrically isolated portions or segments by laser deletion or any other suitable method.

[0071] To prevent material thickness variation at the edge of the electrically connectable layer 12, as shown in Figure 10 and Figure 11As shown, a wrapping layer 52 can be provided around the electrically connected layer 12. The wrapping layer 52 may have an opening to accommodate the outline of the electrically connected layer 12 and a thickness substantially similar to that of the electrically connected layer 12. The wrapping layer 52 and the first interlayer 32 can be fixed together such that they do not change position before material lamination. The wrapping layer may be polyvinyl butyral (PVB), ethylene vinyl acetate (EVA), or an ionomer. In this process, the electrically connected layer 12 is positioned first, and then the wrapping layer 52 is positioned subsequently; however, in some methods, the wrapping layer 52 may be positioned before the electrically connected layer 12 is positioned.

[0072] like Figure 12 and Figure 13 As shown, after positioning the electrically connectable layer 12 and the wrapping interlayer 52, a second interlayer 34 can be disposed above the entire surface of the electrically connectable layer 12 and the wrapping interlayer 52. The second interlayer 34 can be fixed to the wrapping interlayer 52. The second interlayer can be polyvinyl butyral (PVB), ethylene vinyl acetate (EVA), or an ionomer. Subsequently, as... Figure 14 and Figure 15 As shown, a sandwich stack including interlayers 32, 34, 52 and an electrically connectable layer 12 can be positioned between a first glass substrate 30 and a second glass substrate 36. The first glass substrate 30 and the second glass substrate 36 may include soda-lime silicate glass substrates.

[0073] The glass stack can then undergo lamination, including degassing and autoclaving processes. During the degassing process, air inside the glass stack is removed to the outside. To degas the air around the interlayer, the interlayer can have a textured surface prior to the degassing and autoclaving processes. Because the connecting wires have a small diameter and / or are embedded in the interlayer, the air around the connecting wires can be easily extracted as the connecting wires do not substantially obstruct the air extraction. During lamination, the interlayer material can soften and fill any remaining space between the layers.

[0074] Reference Figures 16 to 23 This paper details another method for manufacturing the laminated glass as described above. In this method, connecting wires 22a to 22h are provided after positioning the wrapping interlayer 52 and the electrically connectable layer 12.

[0075] like Figure 16 and Figure 17 As shown, the wrapping layer 52 is positioned on the first interlayer 32 around the area of ​​the electrically connectable layer 12 to be positioned. The wrapping layer may include an opening 54 for fitting around the electrically connectable layer 12. The wrapping layer 52 may be secured to the first interlayer 32. The first interlayer 32 and the wrapping layer 52 may be polyvinyl butyral (PVB), ethylene vinyl acetate (EVA), or an ionomer.

[0076] like Figure 18 and Figure 19 As shown, after positioning the wrapping layer 52, an electrically connectable layer 12, on which busbars 18, 20a to 20g are formed, is disposed within the opening 54 on the first interlayer 32. A portion of the common busbar 18 can be folded over the electrically connectable layer 12 so that when the common busbar 18 is positioned on the first interlayer 32 on the same side as the other busbars 20a to 20g are positioned on the electrically connectable layer 12, it can be connected to the first end 26 of the connecting wire. In some methods, the electrically connectable layer 12 can be positioned on the first interlayer 32 before the wrapping layer 52 is placed around the electrically connectable layer 12.

[0077] like Figure 20 and Figure 21 As shown, with the common busbar 18 configured in a folded manner and the other busbars 20a to 20g disposed in the exposed area of ​​the upper surface of the first electrode layer 42, the connecting wires 22a to 22h are configured to be electrically connected to the busbars 18, 20a to 20g. The first connecting end 26 may extend in a coiled or looped shape to increase the contact area between the connecting wires 22a to 22h and the busbars 18, 20a to 20g in substantially the same manner as described above. The main body portion of the connecting wires 22a to 22h and the second connecting end are constructed in substantially the same manner as described above. In particular, the main body portion of the connecting wires 22a to 22h extends above the wrapping interlayer 52 and may be embedded in the wrapping interlayer 52. An adhesive layer 38 may be provided above the busbars 18, 20a to 20g and the first connecting end 26. The adhesive layer 38 may preferably be made of a conductive material such as silver paste or a carbon-containing adhesive, and the adhesive layer 38 itself may be made of a conductive strip, such as a copper strip that may include conductive paste.

[0078] like Figure 22 As shown, after positioning the connecting wires 22a to 22h, the second interlayer 34 can be positioned on the electrically connectable layer 12 and the wrapping interlayer 52. The second interlayer 34 can be fixed to the wrapping interlayer 52 and can be polyvinyl butyral (PVB), ethylene vinyl acetate (EVA), or an ionomer. Then, as... Figure 23 As shown, a sandwich stack including interlayers 32, 34, 52 and electrically connectable layer 12 can be positioned between a first glass substrate 30 and a second glass substrate 36.

[0079] The glass stack is then subjected to degassing and autoclaving. During the degassing process, air inside the glass stack is smoothly extracted to the outside. During these processes, the interlayer material can soften and fill any remaining spaces between the layers.

[0080] The foregoing description of the present disclosure has been provided for the purposes of enabling those skilled in the art to implement or use the present disclosure. Various modifications to the present disclosure will be readily apparent to those skilled in the art, and the generic principles defined herein can be applied to other variations without departing from the spirit or scope of the disclosure. Furthermore, those skilled in the art will recognize that the foregoing description with respect to specific aspects and / or embodiments of the present disclosure is not intended to limit the scope of the present disclosure but is merely provided as illustration of illustrative forms in which the unique principles of the present disclosure can be employed.

[0081] Moreover, although the elements of the described aspects and / or embodiments can be described or claimed in particular combinations, each combination should be considered as alternative in nature to the other combinations and the disclosure should be understood as comprising each individual combination, permutation, and subset of elements, even if the individual combination is not expressly stated or otherwise described herein. Additionally, it is within the scope of the disclosure that all or some of the acts recited herein can be carried out in the sequence recited or in other sequences that are now known or become known. Furthermore, although the aspects and / or embodiments described herein with reference to the attachments, drawings, components, steps, options, availability, and / or the like is chosen to represent the principles of the disclosure, the disclosure should not be limited to the aspects and / or embodiments.

Claims

1. A laminated glass having an electrically connectable layer, comprising: a first glass substrate and a second glass substrate; an electrically connectable layer; interlayers, wherein the electrically connectable layer is positioned between interlayers; and at least one connecting wire having a first connecting end, a second connecting end, and a body portion positioned between the first connecting end and the second connecting end, wherein the first connecting end of the connecting wire is electrically connected to the electrically connectable layer, wherein the body portion of the connecting wire is positioned within the interlayers, wherein the first connecting end is ring-shaped or zigzag-shaped, and wherein the first connecting end is attached to a busbar on the electrically connectable layer by an adhesive layer or welded to the busbar.

2. The laminated glass according to claim 1, wherein, the electrically connectable layer comprises a switchable film.

3. The laminated glass according to claim 2, wherein, the switchable film comprises a switchable layer core positioned between a first electrode layer and a second electrode layer, wherein the first electrode layer is coated on a first film substrate and the second electrode layer is coated on a second film substrate, and wherein the first electrode layer comprises at least two segments, wherein the segments are electrically isolated from each other and are electrically connected to independent connecting wires via a busbar on each segment, respectively, and wherein the second electrode layer is electrically connected to another connecting wire that is different from the connecting wires electrically connected to the segments, wherein each busbar overlaps the first connecting end of at least one of the connecting wires.

4. A method of making a laminated glass, comprising: placing at least one connecting wire on a first interlayer, wherein each of the at least one connecting wire comprises a first connecting end, a body portion, and a second connecting end, wherein the first connecting end is ring-shaped or zigzag-shaped, and wherein placing the at least one connecting wire comprises embedding the body portion of the connecting wire into the first interlayer, placing an electrically connectable layer over the first interlayer such that at least one busbar on the electrically connectable layer overlaps the first connecting end of the at least one connecting wire and placing a wrap interlayer over the first interlayer around the electrically connectable layer, wherein the first connecting end is attached to the busbar by an adhesive layer or welded to the busbar, and wherein the body portion of the connecting wire is positioned between the first interlayer and the wrap interlayer; placing a second interlayer over the electrically connectable layer and the wrap interlayer to provide an interlayer stack; placing the interlayer stack between a first glass substrate and a second glass substrate to provide a laminated stack; and laminating the laminated stack to provide a laminated glass.

5. A method of making a laminated glass, comprising: placing a wrap interlayer and an electrically connectable layer having at least one busbar on a first interlayer such that the electrically connectable layer fits within the wrap interlayer; placing at least one connecting wire on the wraparound interlayer and the electrically connectable layer, wherein each connecting wire includes a first connecting end, a main body portion, and a second connecting end, wherein the first connecting end overlaps one of the at least one busbar, wherein the first connecting end is ring-shaped or zigzag-shaped, wherein the first connecting end is attached to the busbar by an adhesive layer or welded to the busbar, and wherein the main body portion of each connecting wire is embedded in the wraparound interlayer; placing a second interlayer over the electrically connectable layer and the wraparound interlayer to provide an interlayer stack, wherein the main body portion of the connecting wire extends between the wraparound interlayer and the second interlayer; placing the interlayer stack between a first glass substrate and a second glass substrate to provide a laminate stack; and laminating the laminate stack to provide a laminated glass.

6. A method of making a laminated glass, comprising: placing an electrically connectable layer wrapped by a wraparound interlayer on a first interlayer, wherein the electrically connectable layer having at least one busbar is electrically connected to at least one connecting wire; placing a second interlayer over the electrically connectable layer and the wraparound interlayer to provide an interlayer stack; placing the interlayer stack between a first glass substrate and a second glass substrate to provide a laminate stack; and laminating the laminate stack to provide a laminated glass; wherein each connecting wire has a first connecting end and a second connecting end and a main body portion positioned between the first connecting end and the second connecting end, the first connecting end is ring-shaped or zigzag-shaped, wherein the first connecting end of the connecting wire is electrically connected to the electrically connectable layer, wherein the first connecting end is attached to the busbar by an adhesive layer or welded to the busbar, and wherein the main body portion of the connecting wire is positioned between the wraparound interlayer and one of the first interlayer and the second interlayer. The step of placing the electrically connectable layer wrapped by the wraparound interlayer on the first interlayer having the connecting wire includes: placing the connecting wire on the first interlayer; placing the electrically connectable layer on the first interlayer such that the busbar on the electrically connectable layer overlaps the first connecting end of the connecting wire; and 7. The method of claim 6, wherein, placing the wraparound interlayer on the first interlayer around the electrically connectable layer. The step of placing the electrically connectable layer wrapped by the wraparound interlayer on the first interlayer having the connecting wire includes: placing the connecting wire on the first interlayer; placing the wraparound interlayer on the first interlayer, wherein the wraparound interlayer includes an opening through the wraparound interlayer; and 8. The method of claim 6, wherein, placing the electrically connectable layer on the first interlayer within the opening of the wraparound interlayer such that the busbar on the electrically connectable layer overlaps the first connecting end of the connecting wire. The step of placing the electrically connectable layer wrapped by the wraparound interlayer on the first interlayer having the connecting wire includes: placing an electrically connectable layer on the first interlayer; placing the wraparound interlayer on the first interlayer around the electrically connectable layer; and 9. The method of claim 6, wherein, ​ ​ ​ placing the at least one connection wire on the wrap-around interlayer and the electrically connectable layer, wherein the first connection end of each connection wire overlaps one of the at least one bus bar.

10. The method of claim 6, wherein, placing the electrically connectable layer wrapped by the wrap-around interlayer on the first interlayer with the connection wires includes: placing the wrap-around interlayer on the first interlayer, wherein the wrap-around interlayer includes an opening through the wrap-around interlayer; placing the electrically connectable layer within the opening of the wrap-around interlayer; and placing the at least one connection wire on the wrap-around interlayer and the electrically connectable layer, wherein the first connection end of each connection wire overlaps one of the at least one bus bar.

11. The method of claim 6, wherein, the electrically connectable layer includes at least two electrically isolated sections, wherein each electrically isolated section includes at least one independent bus bar that overlaps an independent connection wire first connection end.

12. The method of claim 7, wherein, placing the at least one connection wire on the first interlayer includes embedding the body portion of the connection wire in the first interlayer.

13. The method of claim 9, wherein, placing the at least one connection wire on the wrap-around interlayer includes embedding the body portion of the connection wire in the wrap-around interlayer.

14. The method of claim 7, wherein, placing an adhesive layer on the first interlayer prior to placing the at least one connection wire, wherein the first connection end is at least partially aligned with the adhesive layer.

15. The method of claim 9, wherein, placing an adhesive layer at least partially over the first connection end on the at least one bus bar after placing the at least one connection wire.

16. The method of claim 6, wherein, the electrically connectable layer includes a light control film.

Images