Sunshade curtain, production method of sunshade curtain, production equipment and vehicle

Abstract

The application discloses a sunshade curtain, a production method and production equipment thereof and a vehicle, and belongs to the technical field of sunshade devices. The sunshade curtain comprises a reflection structure and a sunshade structure. The reflection structure comprises a reflection layer and a carrier layer, and the reflection layer is arranged on the outer side of the carrier layer. The sunshade structure comprises a woven layer, an elastomer and an inner surface layer. The outer side of the woven layer is connected with the inner side of the carrier layer, the inner side of the woven layer is connected with the outer side of the elastomer, and the outer side of the inner surface layer is connected with the inner side of the elastomer. The sunshade curtain can effectively block and reflect sunlight from irradiating the inside of the vehicle, reduce the temperature near the sunroof of the vehicle, reduce the temperature inside the vehicle, and improve the comfort of riding.

Description

Technical Field

[0001] This invention relates to the field of sunshade curtain technology, and in particular to sunshade curtains, sunshade curtain production methods, production equipment and vehicles. Background Technology

[0002] The sunroof occupies a large portion of the roof area of ​​passenger cars, allowing sunlight to directly illuminate the interior when the vehicle is parked outdoors. In the hot summer, the interior temperature can reach as high as 50°C due to direct sunlight, and the temperature near the sunroof can even reach 90°C. This excessively high interior temperature severely affects passenger comfort.

[0003] To address these issues, most existing solutions involve installing a retractable sunshade structure inside the sunroof. When the vehicle is exposed to direct sunlight, the sunshade can be pulled up to block the sun's rays and hopefully reduce the interior temperature. However, currently used sunshades are typically made of ordinary textile materials, and to facilitate retraction, they are usually designed to be very thin. Therefore, existing sunshades do not provide effective heat insulation. In fact, after a period of exposure to direct sunlight, the reduction in interior temperature is not significant. Summary of the Invention

[0004] The present invention aims to at least solve one of the technical problems existing in the prior art. To this end, the present invention provides a sunshade curtain, a method for producing the sunshade curtain, equipment for producing the sunshade curtain, and a vehicle.

[0005] The solution to the technical problem of this invention is:

[0006] Firstly, a sunshade curtain includes:

[0007] A reflective structure includes a reflective layer and a carrier layer, wherein the reflective layer is disposed on the outer side of the carrier layer;

[0008] A sunshade structure includes a woven layer, an elastomer, and an inner surface layer. The outer side of the woven layer is connected to the inner side of the carrier layer, the inner side of the woven layer is connected to the outer side of the elastomer, and the outer side of the inner surface layer is connected to the inner side of the elastomer.

[0009] The present invention has at least the following beneficial effects: When in use, the inner surface layer is set facing the interior of the vehicle, and the reflective layer is set facing the exterior of the vehicle. The reflective layer can block the infrared rays generated by sunlight and the surrounding environment from the outside of the vehicle, reducing the secondary heat radiation into the vehicle after the sunshade curtain's temperature rises due to solar radiation. The elastomer in the sunshade structure has good elasticity, and the sunshade curtain formed by combining with the reflective layer can improve the folding performance of the sunshade curtain while ensuring heat insulation performance, achieving the effect of easy extension and retraction.

[0010] As a further improvement to the above technical solution, the elastomer is a thermoplastic polyurethane elastomer rubber film. The thermoplastic polyurethane elastomer rubber film has the ability to eliminate transmitted light. When cleverly combined with the reflective layer in the same sunshade structure, the sunshade has excellent heat insulation performance and can enhance ultraviolet protection, thereby greatly reducing the interior temperature of the vehicle and improving passenger comfort. Furthermore, the thermoplastic polyurethane elastomer rubber film has good flexibility, which can improve the folding performance of the sunshade while ensuring heat insulation performance.

[0011] As a further improvement to the above technical solution, adhesive layers are respectively provided between the carrier layer and the woven layer, between the woven layer and the elastomer, and between the inner surface layer and the elastomer. By providing adhesive layers, the stability of the connection between the carrier layer and the woven layer, between the woven layer and the elastomer, and between the inner surface layer and the elastomer can be achieved, thereby ensuring the strength of the sunshade and extending its service life.

[0012] As a further improvement to the above technical solution, the adhesive layer is a hot melt adhesive, and the melting temperature of the hot melt adhesive is greater than or equal to 120℃ and less than or equal to 150℃. Because the melting temperature is lower than the operating temperature of ordinary hot melt adhesives, low-temperature application can be achieved, which is more beneficial for processing.

[0013] As a further improvement to the above technical solution, the thickness of each adhesive layer is greater than or equal to 0.1 micrometers and less than or equal to 10 micrometers. Adhesive layers within this thickness range can provide sufficient adhesive strength and allow the sunshade to maintain good folding and storage performance.

[0014] As a further improvement to the above technical solution, the thickness of the reflective layer is greater than or equal to 25 nanometers and less than or equal to 500 nanometers. Within this thickness range, the reflective layer achieves efficient heat reflection, and its bonding with the carrier layer is more stable, extending the service life of the sunshade and controlling its manufacturing costs.

[0015] As a further improvement to the above technical solution, the reflective layer is one of a metal layer, an alloy layer, a metal oxide layer, or an oxide ceramic layer. Metal layers, alloy layers, metal oxide layers, or oxide ceramic layers all have good reflective properties, achieving the effect of blocking sunlight and infrared rays generated by the surrounding environment. This reduces secondary heat radiation into the vehicle interior after the sunshade's temperature rises due to solar radiation, thereby lowering the interior temperature.

[0016] As a further improvement to the above technical solution, the carrier layer is a plastic film. The plastic film, as a carrier for the reflective layer, can have good adhesion to the reflective layer.

[0017] As a further improvement to the above technical solution, the thickness of the plastic film is greater than or equal to 1 micrometer and less than or equal to 25 micrometers. Within this thickness range, the plastic film provides sufficient strength support for the reflective layer, allowing it to be uniformly distributed and well-bonded, thus ensuring the stability and durability of the reflective structure.

[0018] As a further improvement to the above technical solution, the thickness of the inner surface layer is greater than or equal to 0.5 mm and less than or equal to 0.7 mm. Within this thickness range, the inner surface layer possesses sufficient strength and durability, effectively resisting wear, tear, and deformation during daily use. It also reduces the weight and manufacturing cost of the sunshade while maintaining its folding and storage capabilities.

[0019] As a further improvement to the above technical solution, the inner surface layer is a knitted component made of at least one material selected from cotton, linen, polyester, polyvinyl chloride, and non-woven fabric. Using a knitted component as the inner surface layer enhances the aesthetics of the sunshade and increases user comfort.

[0020] As a further improvement to the above technical solution, the thickness of the woven layer is greater than or equal to 0.1 mm and less than or equal to 0.3 mm. Woven layers within this thickness range offer advantages such as a good balance between light blocking and light transmission, excellent durability, lightweight portability, and high cost-effectiveness.

[0021] As a further improvement to the above technical solution, the woven layer is a woven part made of at least one material selected from cotton, linen, polyester, polyvinyl chloride, and nonwoven fabric. A woven layer made of at least one material selected from cotton, linen, polyester, polyvinyl chloride, and nonwoven fabric has relatively stable dimensions and is less prone to deformation or misalignment during use.

[0022] Secondly, embodiments of the present invention also provide a method for producing a sunshade curtain, used to produce a sunshade curtain as described in any of the above technical solutions, the method for producing the sunshade curtain comprising the following steps:

[0023] The elastomer is disposed between the woven layer and the inner surface layer to form the sunshade structure;

[0024] The reflective layer is disposed on the carrier layer to form the reflective structure;

[0025] The inner side of the reflective structure is connected to the outer side of the sunshade structure to form the sunshade curtain.

[0026] The sunshade obtained through the above steps can effectively block and reflect sunlight into the vehicle interior, reduce the temperature near the sunroof, lower the interior temperature, improve passenger comfort, and facilitate the folding and retraction of the sunshade.

[0027] As a further improvement to the above technical solution, the step of disposing the elastomer between the woven layer and the inner surface layer to form the sunshade structure includes:

[0028] Clean the woven layer;

[0029] The elastomer is uniformly bonded onto the cleaned woven layer;

[0030] The inner surface layer is bonded to the elastomer.

[0031] Bonding elastomers onto the cleaned woven layer helps the sunshade remain flat when unfolded, preventing unevenness and improving its abrasion and tear resistance. Adding an inner surface layer to the inside of the elastomer enhances the sunshade's aesthetics and increases user comfort.

[0032] As a further improvement to the above technical solution, the step of depositing the reflective layer on the carrier layer to form the reflective structure includes:

[0033] A plastic film is obtained by casting, wherein the plastic film is the carrier layer;

[0034] The substrate of the reflective layer is deposited onto the plastic film using a vacuum evaporation process, and the reflective layer is formed on the plastic film.

[0035] The thickness of the plastic film obtained by the flow casting method is controllable and can be well integrated with the reflective layer. The thickness of the reflective layer on the plastic film is controllable through the vacuum evaporation process, and the reflective layer is more evenly distributed on the plastic film, ensuring that the reflection effect of the sunshade curtain meets the requirements at all positions.

[0036] As a further improvement to the above technical solution, the step of connecting the inner side of the reflective structure to the outer side of the sunshade structure to form the sunshade curtain includes:

[0037] The outer side of the woven layer is bonded to the inner side of the carrier layer to form a composite.

[0038] The composite material is cut according to the design requirements, and the edges of the cut composite material are sealed or wrapped to form the sunshade curtain.

[0039] The sunshade curtain shall be subject to quality inspection, including but not limited to appearance inspection, size measurement and performance testing.

[0040] By bonding the reflective structure to the sunshade structure, a stable composite is formed. This composite is then cut to size and edge-sealed or wrapped according to the specific needs, resulting in a sunshade that better fits the vehicle's sunroof. This ensures the sunshade's shading performance while reducing material waste and preventing delamination and wear, ultimately leading to a longer lifespan. Sunshades that pass quality inspection are then released to the market, preventing substandard products from entering and protecting consumer rights.

[0041] Thirdly, embodiments of the present invention provide a sunshade production apparatus for performing the sunshade production method as described in any of the technical solutions in the second aspect. The sunshade obtained using the sunshade production apparatus of this embodiment can effectively block and reflect sunlight from illuminating the vehicle interior, reduce the temperature near the sunroof, lower the interior temperature of the vehicle, improve passenger comfort, and facilitate the retraction and extension of the sunshade.

[0042] Fourthly, embodiments of the present invention provide a vehicle including a sunshade as described in any of the technical solutions in the first aspect. The sunshade is installed at the sunroof location of the vehicle. Because the sunshade can effectively block and reflect sunlight from reaching the vehicle interior, it can reduce the temperature near the sunroof, thereby lowering the interior temperature and improving passenger comfort. It also facilitates the retraction and extension of the sunshade. Attached Figure Description

[0043] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly explained below. Obviously, the described drawings are only a part of the embodiments of the present invention, and not all of them. Those skilled in the art can obtain other design schemes and drawings based on these drawings without creative effort.

[0044] Figure 1 This is a schematic diagram of the structure of the sunshade curtain according to an embodiment of the present invention;

[0045] Figure 2 This is a flowchart of a method for producing a sunshade curtain according to an embodiment of the present invention;

[0046] Figure 3 yes Figure 2 Detailed flowchart of step S100;

[0047] Figure 4 yes Figure 2 Detailed flowchart of step S200;

[0048] Figure 5 yes Figure 2 Detailed flowchart of step S300.

[0049] Reference numerals: 101, reflective structure; 102, shading structure; 103, reflective layer; 104, carrier layer; 105, woven layer; 106, thermoplastic polyurethane elastomer rubber film; 107, inner surface layer; 108, adhesive layer. Detailed Implementation

[0050] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0051] In the description of this invention, the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0052] In the description of this invention, "several" means one or more, "more than" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. The use of "first" and "second" in the description is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0053] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0054] Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are all within the scope of protection of the present invention. The various technical features of the present invention can be combined interactively without contradicting each other.

[0055] Reference Figure 1 Firstly, the present invention provides a sunshade curtain that can solve the problem of poor heat insulation effect of existing sunshade curtains. It can effectively block and reflect sunlight from shining into the vehicle interior, reduce the temperature near the sunroof, lower the interior temperature of the vehicle, improve the comfort of riding, and the sunshade curtain is easy to fold.

[0056] In this embodiment, the sunshade includes a reflective structure 101 and a sunshade structure 102. The reflective structure 101 includes a reflective layer 103 and a carrier layer 104. The carrier layer 104 provides a carrier for the reflective layer 103. The reflective layer 103 is disposed on the outer surface of the carrier layer 104, i.e., on the side of the carrier layer 104 facing outwards from the vehicle, through processes such as coating or plating. The sunshade structure 102 includes a woven layer 105, an elastomer, and an inner surface layer 107. The elastomer connects the woven layer 105 and the inner surface layer 107. The outer surface of the woven layer 105 is connected to the inner surface of the carrier layer 104 of the reflective structure 101, with the inner surface of the carrier layer 104 facing inwards from the vehicle. In use, the inner surface layer 107 faces inwards from the vehicle, and the reflective layer 103 faces outwards from the vehicle.

[0057] It is understood that the elastomer can be a polyolefin elastomer, a polyurethane elastomer, etc. In this embodiment, the elastomer is a thermoplastic polyurethane (TPU) film 106.

[0058] It is understandable that when the reflective layer 103 on the surface of the sunshade is subjected to electromagnetic radiation, the reflective layer 103 has not only the ability to reflect, but also the ability to absorb and transmit. The reflectivity is R, the absorptivity is A, and the transmittance is T. The relationship between reflectivity, absorptivity and transmittance is: R + A + T = 100%.

[0059] After absorbing heat, an object will emit energy back out, a process known as electromagnetic radiation, characterized by emissivity E. Kirchhoff's laws state that under thermal equilibrium, the radiant power emitted by an object must equal the radiant power absorbed, i.e., E=A at thermal equilibrium. Therefore, E=1-RT. The reflective layer 103 can block sunlight and infrared radiation from the surrounding environment outside the vehicle, reducing secondary heat radiation into the vehicle interior after the sunshade's temperature rises due to solar radiation, thus significantly lowering the interior temperature.

[0060] TPU can be cast, blown, calendered, or coated into thin films, possessing superior properties such as good elasticity, toughness, wear resistance, cold resistance, and environmental friendliness. The resulting thermoplastic polyurethane elastomer rubber film 106 has the ability to eliminate transmitted light. When the thermoplastic polyurethane elastomer rubber film 106 and the reflective layer 103 are cleverly combined in the same sunshade structure, they can produce additional effects beyond the superposition of single functions.

[0061] First, the combination of the thermoplastic polyurethane elastomer rubber film 106 and the reflective layer 103 enhances the heat insulation performance. The thermoplastic polyurethane elastomer rubber film 106 not only eliminates transmitted light but may also possess certain heat insulation properties, blocking some of the penetration of heat radiation. The reflective layer 103 further reduces heat absorption by reflecting the heat radiation from sunlight. The combination of the two significantly enhances the heat insulation effect of the sunshade, making the interior of the vehicle or other indoor environment cooler.

[0062] Secondly, the combination of the thermoplastic polyurethane elastomer rubber film 106 and the reflective layer 103 enhances ultraviolet (UV) protection. The film structure formed by the TPU material has excellent UV protection performance, blocking UV rays from harming indoor items and people. Although the primary function of the reflective layer 103 is to reflect light, it may also reduce UV transmission to some extent. The combination of the two can form a stronger UV protection barrier.

[0063] Third, the combination of the thermoplastic polyurethane elastomer rubber film 106 and the reflective layer 103 improves the visual effect. The reflective layer 103 can be designed with different colors and patterns as needed to reflect specific light effects, such as a mirror effect or soft diffused light. The thermoplastic polyurethane elastomer rubber film 106, on the other hand, has transparent or translucent properties, allowing for adjustment of light transmittance. The combination of the two can create unique visual effects, meeting the decorative and privacy needs of different scenarios.

[0064] Fourth, the combination of the thermoplastic polyurethane elastomer rubber film 106 and the reflective layer 103 can promote energy conservation and emission reduction. By effectively eliminating transmitted light through the thermoplastic polyurethane elastomer rubber film 106 and effectively eliminating reflected light through the reflective layer 103, the sunshade can significantly reduce the indoor or vehicle interior temperature, thereby reducing the energy consumption of air conditioning and other cooling equipment. This energy conservation and emission reduction effect is of great significance for reducing energy consumption and carbon emissions.

[0065] The combination of thermoplastic polyurethane elastomer rubber film 106 and reflective layer 103 is not merely a simple technological superposition; they complement and promote each other, producing additional effects beyond the sum of their individual functions. This synergistic effect not only enhances the performance and quality of the sunshade but also provides users with a more comfortable, safe, and energy-efficient user experience.

[0066] In some embodiments, adhesive layers 108 are respectively provided between the carrier layer 104 and the woven layer 105, between the woven layer 105 and the thermoplastic polyurethane elastomer rubber film 106, and between the inner surface layer 107 and the thermoplastic polyurethane elastomer rubber film 106, so as to achieve adhesive connection through the adhesive layers 108.

[0067] In some embodiments, the adhesive layer 108 is a hot melt adhesive. It is understood that hot melt adhesives are adhesives that bond by heating from a solid to a liquid state, and then solidify upon cooling using moisture in the air. Once formed, the bonding is irreversible and possesses excellent adhesive strength, ensuring stable connections between the carrier layer 104 and the woven layer 105, between the woven layer 105 and the thermoplastic polyurethane elastomer rubber film 106, and between the inner surface layer 107 and the thermoplastic polyurethane elastomer rubber film 106. The melting temperature of the hot melt adhesive is in the range of 120°C or higher and 150°C or lower, such as moisture-curing reactive polyurethane hot melt adhesives (Polyurethane Reactive, PUR). Because the melting temperature is lower than the operating temperature of ordinary hot melt adhesives (170°C to 200°C), low-temperature application is possible, which is more beneficial for processing.

[0068] In this embodiment, PUR hot melt adhesive is used to form the adhesive layer 108. PUR hot melt adhesive is particularly suitable for bonding heat-sensitive materials (such as plastics), and has excellent heat resistance, cold resistance, water vapor resistance, chemical resistance and solvent resistance. The bonding process is simple and can be applied by roller coating or spraying, and is suitable for various automated assembly lines.

[0069] In some embodiments, the thickness of the adhesive layer 108 is designed to be greater than or equal to 0.1 micrometers and less than or equal to 10 micrometers. Specifically, in this embodiment, the thickness of the PUR hot melt adhesive is in the range of 0.1-10 μm. The determination of this range is usually based on a comprehensive consideration of multiple factors, including material properties, application requirements, cost, and manufacturing process.

[0070] PUR hot melt adhesive possesses excellent adhesion, weather resistance, and elasticity, properties that are optimally utilized at specific thicknesses. An excessively thin adhesive layer 108 fails to provide sufficient bond strength, while an excessively thick layer increases cost and negatively impacts the folding and storage performance of the sunshade. Vehicle sunroof sunshades require specific requirements for light blocking, heat insulation, and durability. The thickness of the PUR hot melt adhesive should be selected based on these requirements to ensure stable bonding of the various structures within the sunshade and maintain consistent performance over long-term use.

[0071] Maintaining the thickness of the PUR hot melt adhesive within the range of 0.1 micrometers to 10 micrometers achieves a fine bonding effect, reducing the impact of the adhesive layer 108 on the overall thickness and weight of the sunshade while maintaining high bond strength. Furthermore, it offers excellent adaptability; the micrometer-level thickness allows the PUR hot melt adhesive to better accommodate the subtle irregularities in various structures within the sunshade, improving the smoothness and aesthetics of the bond. Moreover, using the adhesive layer 108 within this thickness range, while meeting performance requirements, helps save material costs, aligning with environmental protection and sustainable development principles.

[0072] Bonding strength tests were conducted on PUR hot melt adhesives with thicknesses ranging from 0.1 micrometers to 10 micrometers under standard test conditions. The adhesives adhered stably and met or exceeded the industry-specified bonding strength requirements.

[0073] Weather resistance tests were conducted on PUR hot melt adhesives in multiple thickness ranges: After long-term environmental tests including ultraviolet radiation, high temperature and high humidity, no obvious aging, peeling or performance degradation was observed in the PUR hot melt adhesive layer 108 within a thickness range of 0.1 micrometers or more and 10 micrometers or less.

[0074] Folding durability tests were conducted on PUR hot melt adhesives in multiple thickness ranges: During the simulated repeated folding and unfolding of the sunshade, the PUR hot melt adhesive layer 108 in the thickness range of 0.1 micrometers or more and 10 micrometers or less remained intact and did not negatively affect the folding performance and service life of the sunshade.

[0075] In some embodiments, the thickness of the reflective layer 103 is set in the range of greater than or equal to 25 nanometers and less than or equal to 500 nanometers. The thickness of the reflective layer 103 is determined based on a comprehensive consideration of multiple factors, including optical performance, thermal reflectivity, manufacturing cost, and the stability and durability of the material.

[0076] Understandably, the primary function of the reflective layer 103 is to reflect the thermal radiation portion of sunlight, reducing heat entering the vehicle interior. Within its thickness range, the reflective layer 103 can effectively reflect most sunlight. As the thickness of the reflective layer 103 increases, its thermal reflection efficiency typically improves. However, once the thickness reaches a certain point, the improvement in reflection efficiency becomes limited, while manufacturing costs and weight increase significantly. Therefore, a balance needs to be found between thermal reflection efficiency and cost.

[0077] Understandably, a thinner reflective layer 103 could reduce material costs, but it might require more complex processes to ensure its uniformity and stability. The reflective layer 103 needs to bond well with the carrier layer 104 to ensure the stability and durability of the overall structure.

[0078] Specifically, setting the thickness of the reflective layer 103 within the range of greater than or equal to 25 nanometers and less than or equal to 500 nanometers has the following advantages: First, it enables efficient heat reflection. Within this thickness range, the reflective layer 103 can effectively reflect the heat radiation portion of sunlight, significantly reducing the interior temperature and improving driving comfort. Second, manufacturing costs are controllable. With the thickness of the reflective layer 103 within the range of greater than or equal to 25 nanometers and less than or equal to 500 nanometers, manufacturing costs can be reduced while ensuring performance, thus improving the product's cost-effectiveness. Third, within this thickness range, the bonding between the reflective layer 103 and the carrier layer 104 is more stable, maintaining good performance during long-term use and extending the product's lifespan.

[0079] Thermal reflectivity tests show that, under simulated sunlight, the thermal reflectivity of the reflective layer 103 within this thickness range can reach over 97%, effectively reducing heat entering the vehicle interior. Durability tests show that, after a period of use and exposure to harsh environments, the reflective layer 103 within this thickness range did not exhibit significant aging, peeling, or performance degradation, demonstrating good durability and stability.

[0080] In this embodiment, the reflective layer 103 is one of a metal layer, an alloy layer, a metal oxide layer, or an oxide ceramic layer. Examples include aluminum, silver, gold, alumina, and alumina ceramic, with aluminum being the most preferred. The reflective layer 103 is obtained through a vacuum evaporation process. Specifically, the carrier layer 104 is placed in a vacuum evaporation machine, and a vacuum pump is used to evacuate the machine to achieve a vacuum level of 1.3 × 10⁻⁶. -2 ~1.3×10 -3 Pa, heating the crucible to melt and evaporate high-purity aluminum wire into gaseous aluminum at a temperature of 1200℃~1400℃. The gaseous aluminum particles deposit on the surface of the moving carrier layer 104, and after cooling and reduction, form a continuous and bright metallic aluminum layer, which is the reflective layer 103, with a light reflectivity of up to 97%. Specifically, the thickness of the reflective layer 103 is controlled by adjusting the aluminum evaporation rate, the moving speed of the carrier layer 104, and the vacuum level of the coating chamber.

[0081] In this embodiment, the carrier layer 104 is a plastic film. The plastic film has good adhesion to the reflective layer 103 and serves as the carrier for the reflective layer 103. Specifically, it can be a polyethylene terephthalate (PET) film or a cast polypropylene (CPP) film. In addition to excellent physical and mechanical properties, PET and CPP films also possess excellent optical properties, including high transparency, low haze, and high gloss.

[0082] In this embodiment, the plastic film is produced by a casting method. The thickness of the plastic film is greater than or equal to 1 micrometer and less than or equal to 25 micrometers. Within this thickness range, the plastic film provides sufficient strength to support the reflective layer 103, allowing it to be uniformly distributed and well bonded to the reflective layer 103, ensuring the stability and durability of the reflective structure 101. Moreover, during the simulated repeated folding and unfolding of the sunshade, the plastic film within the thickness range of greater than or equal to 1 micrometer and less than or equal to 25 micrometers remains intact and does not negatively affect the folding performance and service life of the sunshade. In addition, the reflective structure 101 formed by the plastic film within this thickness limit and the reflective layer 103 can be stably bonded to the outside of the sunshade structure 102 using PUR hot melt adhesive, providing space for the application of PUR hot melt adhesive.

[0083] In some embodiments, the thickness of the inner surface layer 107 of the sunshade is designed to be greater than or equal to 0.5 mm and less than or equal to 0.7 mm. The thickness of the inner surface layer 107 is set based on a comprehensive consideration of multiple factors, including but not limited to material properties, durability, cost, and manufacturing process. The inner surface layer 107 within the above thickness range has advantages such as a good balance between light blocking and light transmission, excellent durability, lightweight portability, and cost-effectiveness.

[0084] In some embodiments, the inner surface layer 107 is a knitted component, manufactured using a knitting process, and made of at least one material selected from cotton, linen, polyester, polyvinyl chloride, and nonwoven fabric. The knitted inner surface layer 107 possesses specific physical and chemical properties, which are better exhibited in a thickness range greater than or equal to 0.5 mm and less than or equal to 0.7 mm. It is understood that an excessively thin inner surface layer 107 may lack sufficient strength and durability, making it less resistant to wear, tear, and deformation during everyday use. Conversely, an excessively thick inner surface layer 107 would increase the weight and manufacturing cost of the sunshade, and would also affect the ease of folding and storing the sunshade.

[0085] In some embodiments, the thickness of the woven layer 105 is in the range of greater than or equal to 0.1 mm and less than or equal to 0.3 mm. The thickness of the woven layer 105 is set based on a comprehensive consideration of multiple factors, including but not limited to material properties, durability, cost, and manufacturing process.

[0086] In this embodiment, the thickness of the woven layer 105 is 0.2 mm. The 0.2 mm thick woven layer 105 has advantages such as good balance between light blocking and light transmission, excellent durability, lightweight and portability, and high cost-effectiveness.

[0087] In some embodiments, the woven layer 105 is a woven component made of at least one material selected from cotton, linen, polyester, polyvinyl chloride, and nonwoven fabric. The woven layer 105, formed by machine weaving, interweaves yarns perpendicularly in both warp and weft directions, resulting in relatively stable dimensions. It is not easily deformed or distorted during use, thereby maintaining the size and shape of the sunshade.

[0088] In this embodiment, the inner surface layer 107 and the woven layer 105 are disposed on the inner and outer sides of the thermoplastic polyurethane elastomer rubber film 106, forming a stable shading structure 102 that is not easily deformed. This stable shading structure 102 helps the sunshade curtain remain flat when unfolded, avoiding wavy or uneven surfaces. Furthermore, the shading structure 102, in this configuration, has high abrasion resistance and tear resistance, capable of withstanding the pulling and friction during daily use, thereby extending the service life of the sunshade curtain. Regarding light blocking and heat insulation, although the inner surface layer 107 and the woven layer 105 themselves may not directly provide efficient heat insulation performance, they reduce the direct penetration of light and heat to a certain extent. Combined with the thermoplastic polyurethane elastomer rubber film 106, they can further improve the heat insulation effect of the sunshade curtain. In addition, both the inner surface layer 107 and the woven layer 105 have good flexibility, making it easier to fold or roll up the sunshade curtain when storing it, reducing wrinkles.

[0089] Understandably, thermoplastic polyurethane elastomer rubber film 106 possesses properties such as high elasticity, abrasion resistance, weather resistance, and water and stain resistance, and also has a certain degree of self-healing ability. Specifically, high elasticity refers to the excellent elasticity of TPU material, which can quickly return to its original shape when subjected to external force. This characteristic allows the sunshade to maintain its shape and good flatness during unfolding and folding. Abrasion resistance refers to the excellent abrasion resistance of TPU material, which can resist wear and scratches in daily use, maintaining the smoothness of the sunshade surface. Weather resistance refers to the good weather resistance of TPU material, which can maintain stable performance under various climatic conditions and is not prone to aging or deformation. Water and stain resistance refers to the fact that the TPU layer usually has waterproof and stain-resistant functions, which can effectively block rainwater, dust and other pollutants from eroding the sunshade, keeping it clean and beautiful. Self-healing ability refers to the self-healing scratch function of some TPU materials, which can automatically restore the surface smoothness and gloss after being slightly damaged.

[0090] Existing sunshades are typically made of fabric or other non-reflective materials, and their design focuses primarily on blocking the view and providing some heat insulation, but their heat reflectivity is relatively low. They may achieve heat insulation by absorbing some solar radiation and converting it into heat energy (which is then dissipated through conduction, convection, and radiation), and by reducing the transmission of heat radiation through tiny pores in the fabric.

[0091] To further illustrate the superior performance of the sunshade curtain of this embodiment, a comparative experiment was conducted between the sunshade curtain of this embodiment and existing sunshade curtains. The experimental equipment used included an infrared spectrometer or thermal imager, a thermometer, a solar simulator or radiation source, and a data acquisition system. First, both the sunshade curtain of this embodiment and existing sunshade curtains were installed in the experimental equipment to ensure they were functioning properly. Then, a standardized light source and thermal radiation were provided using a solar simulator or radiation source. Next, the thermal reflectivity of the sunshade curtain was measured using an infrared spectrometer or thermal imager under an atmospheric quality of AM 1.5 and a ground irradiance of 1000 W / m². Finally, the temperature changes and thermal reflectivity data of the sunshade curtain of this embodiment and existing sunshade curtains were recorded.

[0092] After the experiment was completed, the experimental data were organized and analyzed, and the average value and standard deviation were calculated to obtain the energy reflectivity of different sunshade curtains to solar radiation. Specifically, the thermal reflectivity of existing sunshade curtains is 30%-50%, while the thermal reflectivity of the sunshade curtain in this embodiment reaches 80%-97%.

[0093] In this embodiment, the thermoplastic polyurethane elastomer rubber film 106 is combined with the woven layer 105 and the inner surface layer 107 to form the sunshade structure 102. This further leverages the characteristics of the thermoplastic polyurethane elastomer rubber film 106, the woven layer 105, and the inner surface layer 107, fully utilizing their advantages. The woven layer 105 and the inner surface layer 107 provide a stable structure and a certain degree of light-blocking effect, while TPU provides high elasticity, abrasion resistance, weather resistance, and waterproof and stain-resistant properties. This combination allows the sunshade to maintain a flat, wrinkle-free appearance when unfolded, and it can be easily folded or rolled up for storage without easily forming wrinkles. In addition, this design improves the durability and service life of the sunshade, making it more suitable as a sunshade solution for parts such as vehicle sunroofs.

[0094] Secondly, the present invention also proposes a method for producing a sunshade curtain, which can produce the sunshade curtain proposed in any of the embodiments of the first aspect above. The obtained sunshade curtain can effectively block and reflect sunlight from shining into the vehicle interior, reduce the temperature near the sunroof of the vehicle, lower the temperature inside the vehicle, and improve the comfort of riding.

[0095] In this embodiment, the method for producing the sunshade curtain includes steps S100, S200, and S300, as described above. Figure 2 Specifically, in this embodiment, a thermoplastic polyurethane elastomer rubber film 106 is used as the elastomer in the sunshade structure 102.

[0096] In step S100, a thermoplastic polyurethane elastomer rubber film 106 is disposed between the woven layer 105 and the inner surface layer 107 to form a sunshade structure 102. With the inner surface layer 107 and the woven layer 105 disposed on the inner and outer sides of the thermoplastic polyurethane elastomer rubber film 106, the resulting sunshade structure 102 is stable and not easily deformed. When the sunshade is unfolded, it remains flat, avoiding wavy or uneven surfaces. Furthermore, it has good tear resistance and abrasion resistance, extending the service life of the sunshade.

[0097] In addition, the inner surface layer 107 and the woven layer 105 can reduce the penetration of light and heat to a certain extent, while the thermoplastic polyurethane elastomer rubber film 106 has a good ability to eliminate transmitted light. The combination of the inner surface layer 107, the woven layer 105 and the thermoplastic polyurethane elastomer rubber film 106 can further improve the heat insulation effect of the sunshade curtain.

[0098] In step S200, the reflective layer 103 is disposed on the carrier layer 104 to form a reflective structure 101. The carrier layer 104 provides space for the reflective layer 103. The reflective layer 103 can reflect most of the sunlight. When disposed on the sunshade, it can block sunlight and infrared rays generated by the surrounding environment from entering the vehicle, reducing secondary heat radiation into the vehicle after the sunshade's temperature rises due to solar radiation, thereby greatly reducing the temperature inside the vehicle.

[0099] In step S300, the inner side of the reflective structure 101 is connected to the outer side of the shading structure 102 to form a sunshade curtain. Since the shading structure 102 is provided with a thermoplastic polyurethane elastomer rubber film 106, and the reflective structure 101 is provided with a reflective layer 103, the combination of the thermoplastic polyurethane elastomer rubber film 106 and the reflective layer 103 enhances heat insulation performance and improves UV protection. The thermoplastic polyurethane elastomer rubber film 106 and the reflective layer 103 complement and promote each other, forming a synergistic effect that not only improves the performance and quality of the sunshade curtain but also provides users with a more comfortable, safe, and energy-saving user experience.

[0100] In some embodiments, step S100 includes steps S110, S120, and S130, referring to... Figure 3 .

[0101] Step S110: Clean the woven layer 105. Cleaning and pre-treating the woven layer 105 ensures that its surface is clean and free of impurities, preparing it for subsequent bonding steps.

[0102] In step S120, the thermoplastic polyurethane elastomer rubber film 106 is uniformly bonded to the cleaned woven layer 105. TPU can be cast, blown, calendered, or coated into a thin film. The thermoplastic polyurethane elastomer rubber film 106 is bonded to the woven layer 105 using an adhesive layer 108 formed by PUR hot melt adhesive, laying the foundation for the subsequent formation of a stable sunshade structure 102. This helps the sunshade curtain remain flat when unfolded, avoiding unevenness, and can improve the abrasion resistance and tear resistance of the sunshade curtain.

[0103] In step S130, the inner surface layer 107 is bonded to the thermoplastic polyurethane elastomer rubber film 106. After the thermoplastic polyurethane elastomer rubber film 106 is bonded to the woven layer 105, the inner surface layer 107 is then bonded on top of the thermoplastic polyurethane elastomer rubber film 106. The inner surface layer 107 not only enhances the aesthetics of the sunshade but also increases the comfort of use.

[0104] Understandably, the inner surface layer 107 is a knitted material, on which patterns and designs can be formed to further enhance the aesthetics of the sunshade.

[0105] In some embodiments, step S200 includes steps S210 and S220, referring to... Figure 4 .

[0106] In step S210, a plastic film is obtained by casting, and the plastic film serves as the carrier layer 104. The plastic film has good adhesion to the reflective layer 103, and as the carrier of the reflective layer 103, it has excellent physical and mechanical properties, as well as excellent optical properties, with good transparency, low haze, and high gloss.

[0107] The carrier layer 104 is obtained by casting, which ensures that the thickness of the plastic film is in the range of 1 micrometer to 25 micrometers. Within this thickness range, the plastic film can better bond with the reflective layer 103, making the setting of the reflective layer 103 more uniform and providing good support for the reflective layer 103.

[0108] Understandably, casting is a plastic film production process. First, the raw material is plasticized and melted by an extruder, and then extruded through a die, allowing the raw material to be cast in sheet form onto the surface of a steadily rotating cooling roller. The film is cooled and shaped on the cooling roller, and then wound up after being pulled and trimmed to finally obtain a plastic film of suitable thickness.

[0109] In step S220, the substrate of the reflective layer 103 is deposited onto the plastic film using a vacuum evaporation process, and the reflective layer 103 is formed on the plastic film.

[0110] In some embodiments, the reflective layer 103 is a metal layer. The plastic film is placed in a vacuum evaporation machine, and a vacuum pump is used to create a vacuum level of 1.3 × 10⁻⁶. -2 ~1.3×10 -3 Pa, heating the crucible to melt and evaporate the high-purity metal wire into gaseous metal at a temperature of 1200℃~1400℃. The gaseous metal particles deposit on the surface of the moving carrier layer 104, and after cooling and reduction, form a continuous and bright metal layer, which is the reflective layer 103, with a light reflectivity of up to 97%. Specifically, the thickness of the reflective layer 103 is controlled by adjusting the metal evaporation rate, the moving speed of the carrier layer 104, and the vacuum level of the coating chamber.

[0111] It is understandable that the reflective layer 103 can also be an alloy layer, a metal oxide layer, an oxide ceramic layer, etc.

[0112] Step S220 ensures that the reflective layer 103 is uniformly disposed on the plastic film, and the thickness of the reflective layer 103 is greater than or equal to 25 nanometers and less than or equal to 500 nanometers. The reflective layer 103 can be stably bonded to the plastic film, and can maintain good performance for a long time during use, thereby improving the service life of the blackout curtain.

[0113] In some embodiments, step S300 includes steps S310, S320, and S330, referring to... Figure 5 .

[0114] In step S310, the outer surface of the woven layer 105 is bonded to the inner surface of the carrier layer 104 to form a composite. By bonding the woven layer 105 to the carrier layer 104, the reflective structure 101 and the sunshade structure 102 can be combined. The resulting sunshade can effectively block and reflect sunlight from entering the vehicle interior, reduce the temperature near the sunroof, lower the interior temperature, and improve passenger comfort.

[0115] In this embodiment, the woven layer 105 and the carrier layer 104 are bonded by an adhesive layer 108 formed by PUR hot melt adhesive. Moreover, the thickness of the adhesive layer 108 is in the range of greater than or equal to 0.1 micrometers and less than or equal to 10 micrometers, which can provide sufficient adhesive strength for the connection between the woven layer 105 and the carrier layer 104, and will not have a negative impact on the folding and storage performance of the sunshade.

[0116] Step S320: Cut the composite material according to design requirements, and seal or bind the edges of the cut composite material to form a sunshade. Cutting the composite material according to the actual size and shape of the vehicle sunroof allows the obtained sunshade to fit the sunroof more closely, ensuring the sunshade's shading performance while reducing material waste. Sealing or binding the edges of the composite material prevents delamination and wear, resulting in a longer service life for the final sunshade.

[0117] Step S330 involves conducting a quality inspection of the sunshade curtains, including but not limited to visual inspection, dimensional measurement, and performance testing. This quality inspection separates qualified from unqualified products, preventing substandard products from entering the market and protecting consumer rights. If the failure rate of sunshade curtains in the same batch is too high, the production equipment needs to be readjusted.

[0118] In some embodiments, the sunshade curtain is further subjected to thermal reflectivity and temperature change tests. The experimental equipment used includes an infrared spectrometer or thermal imager, a thermometer, a solar simulator or radiation source, and a data acquisition system. The specific testing steps are as follows: First, the sunshade curtain of this embodiment is installed in the experimental equipment, ensuring the equipment is functioning properly. Then, a standardized light source and thermal radiation are provided using a solar simulator or radiation source. Next, the thermal reflectivity of the sunshade curtain is measured using an infrared spectrometer or thermal imager under an atmospheric quality of AM 1.5 and a ground irradiance of 1000 W / m². Finally, the temperature change and thermal reflectivity data are recorded. After the test is completed, the test data are processed and analyzed, and the average value and standard deviation are calculated to obtain the energy reflectivity of the sunshade curtain to solar radiation. When the thermal reflectivity and temperature change value of the sunshade curtain meet the preset standards, the thermal reflectivity performance of the sunshade curtain is considered qualified.

[0119] Thirdly, the present invention also provides a sunshade curtain production equipment for producing sunshade curtains as proposed in any one of the embodiments of the first aspect. Using the sunshade curtain production equipment of this embodiment, sunshade curtains can be produced according to the sunshade curtain production method proposed in any one of the embodiments of the second aspect. The obtained sunshade curtain can effectively block and reflect sunlight from irradiating the vehicle interior, reduce the temperature near the vehicle sunroof, lower the vehicle interior temperature, improve the comfort of riding, and the manufactured sunshade curtain has good folding and stretching functions.

[0120] The equipment for producing sunshade curtains includes components for performing steps S100 to S300. These include a cleaning component for step S110, a thermoplastic polyurethane elastomer rubber film 106 film-forming component and a thermoplastic polyurethane elastomer rubber film 106 bonding component for step S120, an inner surface layer 107 bonding component for step S130, a plastic film-forming component for step S210, a vacuum evaporation machine and vacuum pump for step S220, a composite bonding component for step S310, a composite cutting and processing component for step S320, and a quality inspection component for step S330.

[0121] Understandably, the cleaning component can clean the woven layer 105 to ensure its surface is clean. The thermoplastic polyurethane elastomer rubber film 106 forming component can form the thermoplastic polyurethane elastomer rubber film 106 by casting, blowing, calendering, or coating, ensuring the thickness of the thermoplastic polyurethane elastomer rubber film 106 is within a preset range. The thermoplastic polyurethane elastomer rubber film 106 bonding component can apply PUR hot melt adhesive and smoothly bond the formed thermoplastic polyurethane elastomer rubber film 106 to the woven layer 105. The inner surface layer 107 bonding component can apply PUR hot melt adhesive and smoothly bond the inner surface layer 107 to the thermoplastic polyurethane elastomer rubber film 106. The plastic film forming component can form a plastic film by casting, with the thickness of the formed plastic film within a preset range. The vacuum evaporation machine and vacuum pump enable vacuum evaporation of the reflective layer 103, ensuring its uniform deposition on the plastic film with a thickness within a preset range. The composite bonding assembly applies PUR hot melt adhesive, smoothly bonding the reflective structure 101 to the outer side of the sunshade structure 102. The composite cutting and processing assembly cuts the composite and edge-binds or seals its edges. The quality inspection assembly performs quality checks on the obtained sunshade, including visual inspection, dimensional measurement, and performance tests such as strength, toughness, waterproofing, and sun protection.

[0122] Fourthly, embodiments of the present invention also provide a vehicle, which includes a sunshade as described in any of the embodiments of the first aspect. In this embodiment, the sunshade is installed at the sunroof of the vehicle. Since the sunshade can effectively block and reflect sunlight from illuminating the interior of the vehicle, it can reduce the temperature near the sunroof, thereby lowering the interior temperature and improving passenger comfort. Furthermore, the sunshade can be easily folded and extended.

[0123] It is understood that the vehicles mentioned in this embodiment can be private cars, such as sedans, SUVs, MPVs, or pickup trucks. Vehicles can also be commercial vehicles, such as vans, buses, small trucks, or large semi-trailers. Vehicles can be gasoline-powered or new energy vehicles. When a vehicle is a new energy vehicle, it can be a hybrid or a pure electric vehicle.

[0124] The preferred embodiments of the present invention have been described in detail above, but the present invention is not limited to the embodiments described. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the present invention, and these equivalent modifications or substitutions are all included within the scope defined by the claims of this application.

Claims

1. A sunshade curtain, characterized in that, include: A reflective structure includes a reflective layer and a carrier layer, wherein the reflective layer is disposed on the outer side of the carrier layer; A sunshade structure includes a woven layer, an elastomer, and an inner surface layer. The outer side of the woven layer is connected to the inner side of the carrier layer, the inner side of the woven layer is connected to the outer side of the elastomer, and the outer side of the inner surface layer is connected to the inner side of the elastomer. An adhesive layer is provided between the carrier layer and the woven layer, between the woven layer and the elastomer, and between the inner surface layer and the elastomer. The adhesive layer is a moisture-curing reactive polyurethane hot melt adhesive with a melting temperature greater than or equal to 120°C and less than or equal to 150°C. The inner surface layer is a knitted fabric, and the thickness of the inner surface layer is greater than or equal to 0.5 mm and less than or equal to 0.7 mm. The woven layer is a woven part, and the thickness of the woven layer is greater than or equal to 0.1 mm and less than or equal to 0.3 mm. The elastomer is a thermoplastic polyurethane elastomer rubber film.

2. The sunshade curtain according to claim 1, characterized in that, The thickness of each adhesive layer is greater than or equal to 0.1 micrometers and less than or equal to 10 micrometers.

3. The sunshade curtain according to claim 1, characterized in that, The thickness of the reflective layer is greater than or equal to 25 nanometers and less than or equal to 500 nanometers.

4. The sunshade curtain according to claim 1, characterized in that, The reflective layer is one of a metal layer, an alloy layer, a metal oxide layer, or an oxide ceramic layer.

5. The sunshade curtain according to claim 1, characterized in that, The carrier layer is a plastic film.

6. The sunshade curtain according to claim 5, characterized in that, The thickness of the plastic film is greater than or equal to 1 micrometer and less than or equal to 25 micrometers.

7. The sunshade curtain according to claim 1, characterized in that, The inner surface layer is a knitted garment made of at least one of the following materials: cotton, linen, polyester, and polyvinyl chloride.

8. The sunshade curtain according to claim 1, characterized in that, The woven layer is a woven part made of at least one of the following materials: cotton, linen, polyester, and polyvinyl chloride.

9. A method for producing a sunshade curtain, characterized in that, The method for producing the sunshade curtain as described in any one of claims 1 to 8 comprises the following steps: The elastomer is disposed between the woven layer and the inner surface layer to form the sunshade structure; The reflective layer is disposed on the carrier layer to form the reflective structure; The inner side of the reflective structure is connected to the outer side of the sunshade structure to form the sunshade curtain.

10. The method for producing a sunshade curtain according to claim 9, characterized in that, The step of disposing the elastomer between the woven layer and the inner surface layer to form the sunshade structure includes: Clean the woven layer; The elastomer is uniformly bonded onto the cleaned woven layer; The inner surface layer is bonded to the elastomer.

11. The method for producing a sunshade curtain according to claim 9, characterized in that, The step of depositing the reflective layer on the carrier layer to form the reflective structure includes: A plastic film is obtained by casting, wherein the plastic film is the carrier layer; The substrate of the reflective layer is deposited onto the plastic film using a vacuum evaporation process, and the reflective layer is formed on the plastic film.

12. The method for producing a sunshade curtain according to claim 9, characterized in that, The step of connecting the inner side of the reflective structure to the outer side of the sunshade structure to form the sunshade curtain includes: The outer side of the woven layer is bonded to the inner side of the carrier layer to form a composite. The composite material is cut according to the design requirements, and the edges of the cut composite material are sealed or wrapped to form the sunshade curtain. The sunshade curtain shall be subject to quality inspection, including but not limited to appearance inspection, size measurement and performance testing.

13. A vehicle, characterized in that, Includes the sunshade curtain as described in any one of claims 1 to 8.

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