Light-reflecting heat-insulating antistatic sunshade curtain of automobile sunroof and automobile sunroof assembly

Abstract

The invention discloses an automobile sunroof reflective heat-insulation antistatic sunshade curtain and an automobile sunroof assembly, the sunshade curtain adopts a layered composite structure, and is formed by compositing a warp knitted fabric, a composite adhesive film or a black TPU layer and a bottom reflective layer; the composite adhesive film is formed by compounding a black shading adhesive film and a silver reflective adhesive film, the bottom reflective layer is a PET reflective film or a polyester woven reflective fabric, and the black TPU layer is bonded with the warp knitted fabric and the bottom reflective layer through the PUR adhesive layer. The high shading rate is achieved through the black shading adhesive film and the black TPU layer, the silver reflective adhesive film, the micro-prism structure PET reflective film and the aluminum-coated polyester woven reflective fabric form an efficient reflective heat insulation system, the quaternary ammonium salt antistatic agent is added into the functional layer, static accumulation and dust adsorption are inhibited, the product structure is light and thin, the hardness and extensibility are moderate, and the product has the advantages of being light and thin in appearance, high in light shading rate and the like. And the structural adaptability is remarkably improved, the service life is remarkably prolonged, and comprehensive optimization of light reflection, heat insulation, static electricity resistance, high shading, lightness and thinness is achieved.

Description

Technical Field

[0001] This invention belongs to the technical field of automotive sunroof accessories, specifically relating to an automotive sunroof reflective, heat-insulating, and anti-static sunshade curtain and an automotive sunroof assembly. Background Technology

[0002] Existing automotive sunroof sunshades mostly employ conventional multi-layer composite structures, relying solely on a black substrate for light blocking without a dedicated reflective layer. This results in poor heat insulation and a tendency for the interior temperature to rise rapidly. Furthermore, these sunshades lack anti-static design, easily generating static electricity during unfolding, rolling, and use, attracting dust, leading to high cleaning costs and negatively impacting the user experience. Conventional structures also suffer from insufficient light blocking, allowing slight light transmission. Traditional multi-layer structures are thick, and their rigidity and elongation are difficult to control, causing wrinkles during rolling, reducing appearance and lifespan. Currently, the industry struggles to simultaneously address the needs for reflective heat insulation, anti-static properties, and lightweight design, failing to achieve a synergistic improvement in light-blocking performance, structural adaptability, and durability. Summary of the Invention

[0003] The purpose of this invention is to provide a reflective, heat-insulating, and anti-static sunshade curtain for automobile sunroofs and an automobile sunroof assembly, in order to solve the technical defects of existing sunroof sunshade curtains, such as poor heat insulation, easy dust accumulation, insufficient light blocking, and excessive thickness leading to wrinkling.

[0004] To achieve the above objectives, this application provides the following technical solution: The first aspect of this application provides a reflective, heat-insulating, and anti-static sunshade for a car sunroof, which is provided in layers from top to bottom, consisting of a warp-knitted fabric, a composite film, and a bottom reflective layer. The composite film is formed by combining a black light-blocking film and a silver reflective film. The bottom reflective layer is a PET reflective film or a polyester woven reflective fabric; The composite film, PET reflective film, and polyester woven reflective fabric all contain antistatic agents, which are quaternary ammonium salt antistatic agents.

[0005] Furthermore, the composite adhesive film is sandwiched between the warp-knitted fabric and the underlying reflective layer and directly bonded and fixed.

[0006] Furthermore, the thickness of the composite film is 0.15 mm to 0.2 mm.

[0007] Furthermore, the black light-blocking film is made of EVA material, and the silver reflective film is made of PET material.

[0008] Furthermore, the PET reflective film is a PET reflective base film with a microprism structure formed on its surface; The polyester woven reflective fabric is a reflective fabric made by coating an aluminum reflective layer on the surface of a polyester woven substrate.

[0009] A second aspect of this application provides a reflective, heat-insulating, and anti-static sunshade for an automotive sunroof, comprising: Warp-knitted fabric, black TPU layer, and reflective bottom layer; The upper and lower surfaces of the black TPU layer are provided with PUR adhesive layers, and the black TPU layer is bonded to the warp-knitted fabric and the bottom reflective layer respectively through the PUR adhesive layers; The bottom reflective layer is a PET reflective film or a polyester woven reflective fabric; The black TPU layer, PET reflective film, and polyester woven reflective fabric all contain antistatic agents, which are quaternary ammonium salt antistatic agents.

[0010] Furthermore, the PUR adhesive layer is formed by curing a hot-melt PUR adhesive, and the thickness of the PUR adhesive layer is 0.05mm to 0.10mm.

[0011] Furthermore, the black TPU layer is a thermoplastic polyurethane layer with added carbon black opacifier, and its thickness is 0.15mm to 0.30mm.

[0012] Furthermore, the antistatic agent is a quaternary ammonium salt antistatic agent, and it is uniformly dispersed inside the black TPU layer, PET reflective film and polyester woven reflective fabric.

[0013] A third aspect of this application provides an automotive sunroof assembly, characterized in that it comprises: The sunroof body and the sunroof reflective, heat-insulating, and anti-static sunshade curtain as described above; the sunshade curtain is installed on the inside of the sunroof body and is used to reflect light, insulate heat, and provide anti-static protection for the sunroof area.

[0014] Compared with the prior art, the present invention has the following beneficial effects: The product employs a layered composite structure consisting of warp-knitted fabric, a composite film / black TPU layer, and a bottom reflective layer. High light-blocking efficiency is achieved through the black light-blocking film and black TPU layer, addressing the issue of excessive light transmittance in existing products. A highly efficient reflective and heat-insulating system is formed using silver reflective film, micro-prism structure PET reflective film, and aluminum-coated polyester woven reflective fabric, improving the insufficient heat insulation performance of traditional sunshades. The addition of quaternary ammonium salt antistatic agents effectively inhibits the generation and accumulation of static electricity during use, reducing dust adsorption. The reasonable thickness of the composite film and black TPU layer, combined with a PUR adhesive layer, ensures stable bonding, giving the sunshade both lightweight characteristics and suitable softness, hardness, and elongation properties. This reduces wrinkles during roll-up and improves structural adaptability and service life, achieving comprehensive optimization of reflective heat insulation, antistatic properties, high light-blocking, and lightweight design. Attached Figure Description

[0015] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 A schematic diagram of the three-layer composite structure in the reflective, heat-insulating, and anti-static sunshade curtain for automotive sunroofs provided by the present invention. Figure 2 A schematic diagram of the first embodiment of the five-layer composite structure in the reflective, heat-insulating, and antistatic sunshade curtain for automobile sunroofs provided by the present invention; Figure 3 A schematic diagram of the second embodiment of the five-layer composite structure in the reflective, heat-insulating, and antistatic sunshade curtain for automotive sunroofs provided by the present invention; In the diagram: 1. Warp-knitted fabric; 2. Composite film; 3. First reflective film; 4. First PUR adhesive layer; 5. TPU layer; 6. Second PUR adhesive layer; 7. Second reflective film; 8. Reflective fabric. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0018] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0019] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0020] The present invention will now be described in further detail with reference to the accompanying drawings: Example 1 This embodiment provides a reflective, heat-insulating, and anti-static sunshade for a car sunroof, which has a three-layer composite structure, such as... Figure 1As shown, from top to bottom, the structure is layered as follows: warp-knitted fabric 1, composite film 2, and first reflective film 3. The warp-knitted fabric 1 and composite film 2, as well as the composite film 2 and first reflective film 3, are bonded and fixed with PUR hot melt adhesive to form an integrated composite structure. The overall thickness is controlled between 0.45mm and 0.6mm. While ensuring reflective, heat insulation, light blocking, and antistatic functions, the structure is made lightweight and thin, mainly suitable for the conventional sunroof usage scenarios of mid-to-low-end models.

[0021] Among them, warp-knitted fabric 1 is the surface layer of the sunshade, which is in direct contact with the interior environment of the car. It is made of polyester warp-knitted fabric with a yarn fineness of 75D / 36F, a fabric density of 28 stitches / inch, and a thickness controlled between 0.15mm and 0.2mm. This specification of polyester warp-knitted fabric has excellent abrasion resistance, tensile strength, and folding resistance. It can withstand the friction and stretching during the long-term repeated opening and closing of the car sunshade, reducing the probability of adverse phenomena such as fabric pilling, fuzzing, and tearing during use.

[0022] The outer surface of the warp-knitted fabric 1 undergoes a skin-friendly treatment, resulting in a smooth and soft texture that avoids discomfort such as scratches and itching when in contact with passengers, thus enhancing the in-vehicle user experience. Simultaneously, the skin-friendly treatment of the warp-knitted fabric 1 results in a more uniform and smooth microstructure, effectively increasing the bonding contact area with the PUR hot melt adhesive and composite film 2, strengthening interfacial adhesion, improving interlayer bonding stability, and reducing the risk of interlayer separation and delamination during long-term use.

[0023] The composite film 2 integrates light-blocking, reflective heat insulation and basic antistatic functions. It is formed into an integrated structure by hot pressing a black light-blocking layer and a silver reflective antistatic layer. The total thickness is controlled between 0.15mm and 0.2mm, which matches the thickness of the warp-knitted fabric 1 and the first reflective film 3, ensuring that the overall structure is thin and uniform, without any problems of excessive thickness or uneven softness and hardness in certain areas.

[0024] The black light-blocking layer is made of EVA material, with 15% to 20% carbon black light-blocking agent evenly added to the EVA substrate. The carbon black light-blocking agent is evenly dispersed in the substrate, which can fully absorb the incident light from the outside and eliminate the phenomenon of micro-transmission, meeting the needs of drivers and passengers for a fully light-blocking environment during lunch breaks, when children are riding in the car, and when driving at night.

[0025] Meanwhile, EVA material has good thermoplasticity and bonding properties, which can achieve stable composite with the silver reflective antistatic layer, and can also form reliable bonding with the warp-knitted fabric 1 through PUR hot melt adhesive.

[0026] The silver reflective antistatic layer is made of PET material, and a continuous and dense aluminum layer is formed on the surface through a vacuum evaporation process. The thickness of the aluminum layer is controlled between 50nm and 80nm, which can reduce heat absorption and conduction from the source and improve the problem of rapid temperature rise in the car interior caused by heat absorption of traditional black substrates.

[0027] A quaternary ammonium salt antistatic agent of 2% to 3% is incorporated into the PET substrate. The antistatic agent is uniformly dispersed within the substrate, forming a continuous conductive path on the surface of the silver reflective antistatic layer, thereby controlling the surface resistance of the composite film 2 to within 10 ohms. 9 ~10¹¹Ω, meeting the industry standard for electrostatic protection of automotive interiors, can quickly release static electricity generated during unfolding, winding and use, and inhibit dust adsorption.

[0028] The black light-blocking layer and the silver reflective antistatic layer are hot-pressed together to form an integral composite film 2. After hot pressing, the composite strength is not less than 5N / 25mm. The composite film 2 is free from defects such as interlayer separation, wrinkling, and bubbles, and its structure and function remain stable during long-term use.

[0029] The first reflective film 3 is the bottom functional layer of a three-layer structure. It uses a PET reflective base film with a thickness controlled between 0.15mm and 0.2mm. The surface of the first reflective film 3 is formed with a microprism structure. The height of the microprism is 50μm to 80μm and the spacing between the microprisms is 100μm to 120μm. It can reflect a small amount of solar radiation heat that passes through the silver reflective and antistatic layer of the composite film 2, forming a double reflective heat insulation structure with the composite film 2, which greatly improves the overall heat insulation effect.

[0030] PET reflective base film has excellent dimensional stability. It does not shrink, warp, or deform significantly in high and low temperature environments ranging from -40℃ to 80℃, which can ensure the overall structural dimensional stability of the sunshade and avoid problems such as interlayer wrinkles, adhesion failure, and uneven unfolding caused by deformation of the base material.

[0031] In this embodiment, the manufacturing process of the three-layer composite structure sunshade curtain is divided into a pretreatment stage, an interlayer bonding stage, and a post-treatment stage.

[0032] The pretreatment stage is mainly used to remove impurities and oil stains from the surfaces of the warp-knitted fabric 1, the composite adhesive film 2, and the first reflective film 3, thereby improving surface activity. At the same time, it completes the pre-composite bonding of the composite adhesive film 2, reducing the occurrence rate of defects such as bubbles, insufficient adhesive, and interlayer separation during the subsequent bonding process.

[0033] When cleaning and degreasing the warp-knitted fabric 1, a 5% sodium hydroxide solution is used to completely immerse the warp-knitted fabric 1 in the solution. The immersion temperature is controlled at 60℃~70℃ and the immersion time is 20 minutes~30 minutes. Saponification removes impurities such as oil, sizing agents, and dust that adhered during weaving and storage.

[0034] After soaking, the surface of the warp-knitted fabric 1 is repeatedly rinsed with deionized water until the pH value is neutral. Then, it is dried in a drying equipment at 80℃~90℃ to make the moisture content of the warp-knitted fabric 1 less than 5%, so as to avoid the internal moisture from vaporizing and forming bubbles during hot pressing and bonding, which would affect the interlayer bonding strength and appearance flatness.

[0035] During the pre-lamination of the composite film 2, the black light-blocking layer and the silver reflective antistatic layer are laid flat in the hot press equipment, with the black light-blocking layer facing up and the silver reflective antistatic layer facing down. The hot press temperature is set to 120℃~130℃, the pressure is 0.3MPa~0.5MPa, and the hot press time is 10 seconds~15 seconds to complete the pre-lamination of the two layers of film.

[0036] After pre-lamination, the composite film 2 is tested for composite strength. The composite strength is not less than 5N / 25mm. If it does not meet the requirements, the hot pressing parameters are readjusted and the film is laminated again to ensure that no interlayer separation occurs in subsequent use.

[0037] During the pretreatment of the first reflective film 3, a lint-free cloth dipped in anhydrous ethanol is used to gently wipe the upper and lower surfaces of the first reflective film 3 to remove impurities such as dust, fingerprints, and oil stains. After wiping, it is allowed to air dry naturally without high-temperature drying to prevent the microprism structure from being deformed or damaged by heat and to ensure stable reflective performance.

[0038] For interlayer bonding, isocyanate-based PUR hot melt adhesive is used as the adhesive, and the warp-knitted fabric 1, composite adhesive film 2, and first reflective film 3 are bonded layer by layer through a step-by-step hot pressing process. The PUR hot melt adhesive has high bonding strength, excellent high and low temperature resistance, and moderate elasticity after curing, making it suitable for the use environment of automotive sunroofs. The melting temperature is 120℃~140℃, and the viscosity is controlled at 1500mPa at 130℃. s~2000mPa s, which makes it easy to apply glue evenly and prevents glue overflow.

[0039] The first step is to lay the pre-treated warp-knitted fabric 1 flat on the lower template of the hot press equipment. The temperature of the lower template is set to 55℃~60℃ to prevent the warp-knitted fabric 1 from shrinking and deforming due to heat. PUR hot melt adhesive is evenly applied to the bonding surface of the warp-knitted fabric 1 and the composite adhesive film 2. The amount of adhesive applied is controlled at 15g / m²~20g / m² to ensure uniform coating and no missed coating, adhesive accumulation, or adhesive breakage.

[0040] After the adhesive is applied, the pre-laminated composite film 2 is placed over the adhesive surface, so that the black light-blocking layer is attached to the warp-knitted fabric 1 and the silver reflective antistatic layer faces downward.

[0041] Start the template on the hot press equipment, set the upper template temperature to 130℃~140℃, apply pressure of 0.4MPa~0.6MPa, and hot press time of 15 seconds~20 seconds to complete the bonding of warp-knitted fabric 1 and composite adhesive film 2. After bonding, let it stand and cool to room temperature, check the interlayer bonding status. If there are no bubbles, wrinkles, separation, or missing adhesive, it is qualified.

[0042] The second step involves repeating the adhesive application process on the lower surface of the silver reflective and antistatic layer of the composite adhesive film 2, maintaining an adhesive application amount of 15g / m² to 20g / m², ensuring uniform application. The pre-treated first reflective film 3 is then placed over the adhesive-coated surface, with the microprism structure facing outwards to ensure the reflective surface faces the direction of external solar radiation, thus improving heat insulation efficiency. The hot-pressing equipment is restarted, maintaining the same parameters as the first step: upper template temperature 130℃ to 140℃, pressure 0.4MPa to 0.6MPa, and hot-pressing time 15 to 20 seconds. This completes the bonding of the composite adhesive film 2 and the first reflective film 3, ultimately forming a three-layer composite structure consisting of the warp-knitted fabric 1, the composite adhesive film 2, and the first reflective film 3.

[0043] After interlayer bonding is completed, the three-layer composite structure undergoes initial inspection, with test indicators including overall thickness and interlayer peel strength. The overall thickness is controlled between 0.45mm and 0.6mm, and the peel strength of each layer is greater than 4N / 25mm. Unqualified products are reworked.

[0044] Post-processing includes three steps: curing, cutting, and heat sealing. This process fully cures the PUR hot melt adhesive, improves interlayer bonding stability and environmental resistance, and transforms the semi-finished product into a finished product that fits the skylight size, preventing edge yarns from unraveling.

[0045] During the curing stage, the semi-finished fabric curtain after interlayer bonding is placed in a constant temperature and humidity equipment for curing. The curing temperature is 50℃~60℃, the humidity is 40%~50%, and the curing time is 24 hours~36 hours. Under this environment, the PUR hot melt adhesive fully undergoes a curing and cross-linking reaction, the molecular chain structure becomes more stable, and the interlayer bonding strength and high and low temperature resistance are significantly improved, ensuring that the sunshade curtain does not experience interlayer separation or delamination problems under extreme environments.

[0046] During the cutting process, CNC cutting equipment is used to cut the cured semi-finished product according to the actual size of the sunroof of different car models. The cutting accuracy is controlled within ±0.5mm to ensure that the sunshade can accurately fit the sliding guide rail of the sunroof frame and avoid problems such as installation difficulties, unfolding jams, and uneven rolling due to size deviations.

[0047] During the heat-sealing stage, the edges of the cut sunshade curtain are heat-sealed. The heat-sealing equipment heats the edges to 200℃~220℃ for 5 seconds to 10 seconds, so that the polyester fibers on the edge melt and bond together, preventing problems such as yarn unraveling, edge fuzzing, and rough edges during use, while improving edge abrasion resistance and overall service life.

[0048] This embodiment of the three-layer composite structure sunshade curtain achieves a comprehensive effect of 100% light blocking, high-efficiency reflective heat insulation, anti-static properties, and a lightweight and adaptable structure through the structural combination and functional synergy of warp-knitted fabric 1, composite film 2, and first reflective film 3.

[0049] In terms of light blocking, the 15% to 20% carbon black light blocking agent in the black light blocking layer of the composite film 2 can completely absorb visible light from the outside. The microprism structure of the first reflective film 3 reflects a small amount of unabsorbed light a second time. The absorption and reflection work together to achieve a 100% light blocking rate with no light transmission points, solving the defects of insufficient light blocking and slight light transmission of traditional sunshade curtains and meeting the light blocking needs of all scenarios.

[0050] In terms of heat insulation, the aluminum layer on the surface of the silver reflective antistatic layer of the composite film 2 reflects more than 85% of solar radiation heat, and the microprism structure of the first reflective film 3 achieves secondary high-efficiency reflection. The dual reflective structure significantly reduces heat conduction. Under the conditions of a sunny summer day with an ambient temperature of 35℃ and a light intensity of 1000W / m², the interior temperature of the vehicle equipped with the sunshade of this embodiment is 10℃~12℃ lower than that of the traditional black base material sunshade, significantly improving the thermal environment inside the vehicle, reducing air conditioning energy consumption, and enhancing driving comfort.

[0051] Regarding antistatic properties, the quaternary ammonium salt antistatic agent inside the composite film 2 forms a continuous conductive path, and the surface resistance is stabilized at 10. 9 With an impedance of ~10¹¹Ω, it can quickly release static electricity generated by friction and inhibit dust adsorption. After 30 days of continuous use in a dry environment with an air humidity of 30% to 40%, the amount of dust adhering to the surface is only 1 / 5 of that of traditional solutions, significantly reducing the frequency and cost of cleaning and maintenance. There is no electrostatic discharge phenomenon, resulting in an excellent user experience.

[0052] In terms of structural adaptation, the overall thickness is 0.45mm to 0.6mm, which is lighter and thinner than the traditional three-layer structure. By controlling the amount of adhesive and hot pressing parameters, the elongation rate is controlled at 15% to 20%. According to GB / T3923.1-2013 testing, the Shore hardness is controlled at 60HA to 70HA, which matches the motion characteristics of the sunroof retraction mechanism. The retraction is smooth without wrinkles or warping, and the unfolding is flat. At the same time, it reduces the load on the mechanism and extends the service life of the sunroof mechanism.

[0053] Example 2 This embodiment provides another type of reflective, heat-insulating, and anti-static sunshade for automotive sunroofs, which has a five-layer composite structure, such as... Figure 2As shown, from top to bottom, the structure consists of warp-knitted fabric 1, first PUR adhesive layer 4, black TPU layer 5, second PUR adhesive layer 6, and second reflective film 7. Warp-knitted fabric 1 and black TPU layer 5 are bonded together by hot-pressing with the first PUR adhesive layer 4, and black TPU layer 5 and second reflective film 7 are bonded together by hot-pressing with the second PUR adhesive layer 6. The overall thickness is controlled between 0.45mm and 0.7mm. While achieving 100% light blocking, reflective heat insulation, and antistatic properties, it also improves structural elasticity and stability, primarily suitable for large-size panoramic sunroof applications.

[0054] In this embodiment, the material, specifications, and performance of the warp-knitted fabric 1 are exactly the same as those in Embodiment 1. It is made of 75D / 36F polyester warp-knitted fabric with a density of 28 needles / inch and a thickness of 0.15mm to 0.2mm. The surface is treated with a skin-friendly finish and has excellent abrasion resistance, tensile strength, skin-friendliness, and bonding stability. Further details will not be provided here.

[0055] The first PUR adhesive layer 4 and the second PUR adhesive layer 6 are a five-layer adhesive layer, both of which are formed by curing isocyanate-based PUR hot melt adhesive. They are the same adhesives used in Example 1, ensuring stable bonding strength, temperature resistance, and aging resistance.

[0056] After curing, the thickness of both adhesive layers is controlled between 0.05mm and 0.1mm, and the single-layer bonding strength is greater than 5N / 25mm. This enables reliable bonding between the warp-knitted fabric 1, the black TPU layer 5, and the second reflective film 7. The ultra-thin thickness helps to control the overall structure to be thin and light, and avoids the overall structure from being too hard or too thick due to excessive adhesive layers.

[0057] The black TPU layer 5 uses a thermoplastic polyurethane (TPU) film with added carbon black opacifier, and the thickness is controlled between 0.15mm and 0.2mm. The amount of carbon black opacifier added is 20% to 25%, which is higher than the amount added in conventional TPU layers, ensuring that the opacity reaches 100%, thus solving the defects of white TPU being slightly translucent and black TPU being insufficiently opaque in the traditional five-layer structure.

[0058] TPU material possesses excellent elasticity, flexural strength, and fatigue resistance, with an elongation at break of no less than 400%. Tests show it effectively buffers tension during the unfolding and rewinding of sunshades, reducing the risk of fabric stretching, layer separation, and wrinkling, thus improving structural stability and wrinkle resistance. Furthermore, TPU has a temperature resistance range of -40℃ to 80℃, excellent aging resistance, and is not prone to embrittlement, deformation, or cracking in automotive outdoor environments. It also exhibits good compatibility with PUR hot melt adhesives, resulting in high bonding strength.

[0059] The second reflective film 7 is the bottom reflective, heat-insulating, and antistatic layer. Its material, structure, and performance are completely identical to the first reflective film 3 in Example 1. It uses a PET reflective base film with a thickness of 0.15mm to 0.2mm, and its surface has a microprism structure, resulting in a reflectivity of not less than 90% and a surface resistivity of 10 Ω·cm. 9 ~10¹¹Ω, which can achieve secondary reflective heat insulation and antistatic functions, and together with the black TPU layer 5, it forms a highly efficient heat insulation system that combines light blocking and reflection, which will not be elaborated here.

[0060] The five-layer composite structure preparation process in this embodiment is also divided into three stages: pretreatment, interlayer bonding, and post-treatment. Based on the first embodiment, adjustments are made, with a focus on adding plasma surface treatment to the black TPU layer 5, optimizing hot pressing parameters and edge heat sealing temperature, to ensure reliable interlayer bonding, excellent elasticity, and accurate dimensions.

[0061] In the pretreatment stage, the pretreatment of warp-knitted fabric 1 is completely consistent with that in Example 1. It is soaked in 5% sodium hydroxide solution at 60℃~70℃ for 20 minutes~30 minutes, rinsed with deionized water until neutral, and dried at 80℃~90℃ until the moisture content is <5%.

[0062] The black TPU layer 5 has low surface tension, and direct bonding can easily lead to interlayer separation. Therefore, plasma surface treatment is performed. The black TPU layer 5 is laid flat on a plasma treatment device with a treatment power of 300W to 400W and a treatment time of 5 to 10 seconds. The plasma etches and activates the surface, improving roughness and surface activity, thereby increasing the adhesion to the first PUR adhesive layer 4 and the second PUR adhesive layer 6 by more than 30% and reducing the risk of delamination.

[0063] The pretreatment of the second reflective film 7 is the same as in Example 1: the surface impurities are wiped off with anhydrous ethanol and then air-dried to protect the microprism structure.

[0064] Pretreatment of the first PUR adhesive layer 4 and the second PUR adhesive layer 6: Preheat the PUR hot melt adhesive to 100℃~110℃ in a constant temperature heating device to soften the adhesive material and facilitate uniform application.

[0065] During the interlayer bonding stage, a step-by-step hot-pressing process is adopted, and the parameters of the two hot-pressing processes are kept consistent to ensure uniform interlayer bonding strength.

[0066] The first step involves laying the pre-treated warp-knitted fabric 1 flat on a hot-press template at a temperature of 55℃~60℃. A first PUR adhesive layer 4 is then uniformly coated onto its lower surface with PUR hot melt adhesive at a rate of 15g / m²~20g / m². Next, a plasma-treated black TPU layer 5 is placed over the adhesive layer. The hot-press equipment is then activated, with the upper template temperature at 130℃~140℃ and the pressure at 0.4MPa~0.6MPa for 15~20 seconds, completing the bonding between the warp-knitted fabric 1 and the black TPU layer 5. After cooling, an inspection is performed to ensure no bubbles or wrinkles are present.

[0067] The second step involves uniformly coating the lower surface of the black TPU layer 5 with PUR hot melt adhesive to form the second PUR adhesive layer 6, using the same amount of adhesive as in the first step. The pre-treated second reflective film 7 is then placed over the adhesive-coated surface, with the microprism structure facing down. The film is then hot-pressed again using the exact same hot-pressing parameters as in the first step to complete the bonding between the black TPU layer 5 and the second reflective film 7, forming a five-layer composite structure.

[0068] After the interlayer bonding is completed, an initial inspection is carried out. The overall thickness is 0.45mm to 0.7mm, and the peel strength between each layer is >5N / 25mm. Unqualified products are reworked.

[0069] The curing treatment is the same as in Example 1, curing at 50℃~60℃ and humidity 40%~50% for 24 hours~36 hours to fully cure the PUR hot melt adhesive.

[0070] The cutting process is the same as in Example 1, and CNC cutting is performed according to the size of the large panoramic sunroof with an accuracy of ±0.5mm.

[0071] During heat sealing, since the black TPU layer 5 has better heat resistance than the composite film 2, the heat sealing temperature is increased to 220℃~240℃ and the heat sealing time is 5 seconds~10 seconds, so that the edge polyester fibers and TPU can be fully melted and bonded, preventing the yarn from coming apart and improving the edge sealing and abrasion resistance.

[0072] This embodiment of the five-layer composite structure retains all the advantages of Embodiment 1, while further improving elasticity, stability, and light-shielding reliability.

[0073] The 20%–25% carbon black opaque agent in the black TPU layer 5 completely absorbs visible light, and the second reflective film 7 provides secondary reflection, achieving long-term stable 100% opacity without light transmission or attenuation. This solves the defects of traditional five-layer structures, such as unstable opacity and susceptibility to tension.

[0074] The second reflective film 7 has a reflectivity of ≥90%, and works in synergy with the black TPU layer 5 to provide heat insulation. Under the same lighting conditions, the interior temperature is 8℃~10℃ lower than that of the traditional five-layer solution, resulting in a significant heat insulation effect.

[0075] The surface resistance of the second reflective film 7 is 10. 9 ~10¹¹Ω, rapidly releases static electricity, lasts 30 days in a dry environment, and the amount of dust adhering is 1 / 4 of that of traditional solutions, demonstrating excellent antistatic effect.

[0076] The black TPU layer 5 has high elasticity, resulting in an overall elongation rate of 25% to 30% and a Shore hardness of 55HA to 65HA. It has strong buffering capacity and an overall thickness of 0.45mm to 0.7mm, which is lighter and thinner than the traditional five-layer solution. The roll-up wrinkle rate is reduced by more than 80%, making it suitable for large-size panoramic sunroofs. It unfolds flat without warping, has strong tear resistance, and a longer service life.

[0077] Example 3 This embodiment provides a third type of reflective, heat-insulating, and anti-static sunshade for automotive sunroofs, which has a five-layer composite structure, such as... Figure 3 As shown, from top to bottom, the layers are: warp-knitted fabric 1, first PUR adhesive layer 4, black TPU layer 5, second PUR adhesive layer 6, and reflective fabric 8. The difference from Example 2 is that the second reflective film 7 is replaced with reflective fabric 8, with the overall thickness controlled between 0.6mm and 0.9mm. While maintaining 100% light blocking, efficient heat insulation, and high elasticity, it further improves antistatic properties, wear resistance, and appearance customization capabilities, making it suitable for mid-to-high-end vehicles and high-frequency usage scenarios such as taxis and ride-hailing vehicles.

[0078] In this embodiment, the materials, specifications, and performance of the warp-knitted fabric 1, the first PUR adhesive layer 4, the black TPU layer 5, and the second PUR adhesive layer 6 are exactly the same as in Embodiment 2, and will not be repeated here.

[0079] The reflective fabric 8 is the core improved component of this embodiment. It is the bottom reflective, heat-insulating, anti-static, and wear-resistant functional layer. It is made of polyester woven reflective fabric with a yarn fineness of 50D / 24F, a fabric density of 32 needles / inch, and a thickness controlled between 0.2mm and 0.25mm. It has high structural strength and wear resistance superior to PET reflective film.

[0080] The reflective fabric 8 has a continuous and dense aluminum layer formed on its surface through a coating process. The aluminum layer is 80nm to 100nm thick and has a reflectivity of not less than 88%, which can efficiently reflect solar radiation heat and achieve stable heat insulation. 3% to 4% of a quaternary ammonium salt antistatic agent is mixed into the polyester substrate, a higher addition amount than in Examples 1 and 2, forming a denser conductive path on the surface and controlling the surface resistance to 10 Ω·cm. 8 ~10¹ 0 Ω provides superior antistatic properties, faster static discharge, and less dust adsorption.

[0081] Polyester woven structures have excellent resistance to folding, abrasion, and friction. They are not easily damaged by repeated unwinding and winding over a long period of time, and the reflective layer is not easily worn. Their service life is significantly longer than that of film-type reflective layers, making them suitable for high-frequency use scenarios.

[0082] Based on the process of Example 2, adjustments were made to the woven characteristics of reflective fabric 8, including adding pre-shrinkage treatment, optimizing hot pressing parameters, and extending curing time to ensure stable bonding, no shrinkage, and no wrinkles.

[0083] In the pretreatment stage, the pretreatment of warp-knitted fabric 1 and black TPU layer 5 is exactly the same as in Example 2.

[0084] During the pretreatment of reflective fabric 8, which has potential shrinkage, a pre-shrinking treatment is first performed by immersing it in hot water at 80℃~90℃ for 10 to 15 minutes and then air-drying it naturally. The pre-shrinkage rate is controlled at 2%~3% to eliminate the risk of shrinkage and wrinkles during subsequent use. After pre-shrinking, wipe the surface with anhydrous ethanol to remove dust and oil stains, and then air-dry it for later use.

[0085] The pretreatment of the first PUR adhesive layer 4 and the second PUR adhesive layer 6 is the same as in Example 2, and they are preheated to 100℃~110℃.

[0086] The bonding process and parameters between the warp-knitted fabric 1 and the black TPU layer 5 are exactly the same as in Example 2.

[0087] The black TPU layer 5 is bonded to the reflective fabric 8. A second PUR adhesive layer 6 is formed by coating the underside of the black TPU layer 5 with PUR hot melt adhesive at a rate of 15g / m² to 20g / m². The pre-shrunken and cleaned reflective fabric 8 is then placed over the adhesive-coated surface, with the aluminum layer facing down. The hot-pressing temperature and pressure are increased, with the temperature set to 140℃ to 150℃ and the pressure to 0.5MPa to 0.7MPa, for a duration of 15 to 20 seconds. This ensures the PUR hot melt adhesive fully impregnates the woven seams, guaranteeing a tight, gap-free bond between layers. After cooling, the surface is inspected for bubbles, wrinkles, and delamination.

[0088] After the interlayer bonding is completed, an initial inspection is conducted. The overall thickness is 0.6mm to 0.9mm. The bonding strength between the black TPU layer 5 and the reflective cloth 8 is >6N / 25mm, and the bonding strength between the remaining layers is >5N / 25mm. Unqualified products are reworked.

[0089] During the curing process, due to the large gaps between the 8 fibers of the reflective fabric, the curing time is extended to 36 to 48 hours, with a temperature of 50 to 60°C and a humidity of 40% to 50%, so that the PUR hot melt adhesive can fully bond with the polyester fibers and TPU, thereby improving the interlayer stability.

[0090] The cutting and heat-sealing processes are the same as in Example 2, with a cutting accuracy of ±0.5mm, a heat-sealing temperature of 220℃~240℃, and a time of 5 seconds~10 seconds.

[0091] Warp-knitted fabric 1 can be processed with jacquard, printing, imitation suede, carbon fiber, wood grain and other textures before pretreatment, to match the interior style of mid-to-high-end car models, achieve coordination and unity with the car interior environment, and enhance the added value of the product.

[0092] Based on Example 2, this embodiment further improves antistatic properties, wear resistance, and appearance compatibility to meet the needs of high quality, personalization, and high-frequency use. Specifically, the black TPU layer 5 and the reflective fabric 8 work together to achieve stable 100% light blocking with no micro-transmission.

[0093] The reflective fabric has an aluminum layer with a reflectivity of ≥88%. When combined with the black TPU layer 5, the interior temperature is 9℃~11℃ lower than the traditional five-layer solution, resulting in excellent heat insulation.

[0094] The high content of antistatic agent in reflective fabric 8 reduces the surface resistance to as low as 10. 8 ~10¹ 0 Ω, after 60 days of continuous use in a dry environment, the amount of dust adhering is only 1 / 8 of that of traditional solutions, with almost no obvious dust accumulation, and the cleaning and maintenance costs are extremely low.

[0095] The woven structure of the reflective fabric has a wear resistance far superior to that of PET reflective film. After 1,000 friction tests, the reflectivity decreases by less than 5%, which is much lower than the attenuation rate of more than 20% of traditional reflective film. Its service life is extended by more than 30% compared with Example 2, making it suitable for high-frequency use scenarios in commercial vehicles.

[0096] Warp-knitted fabric 1 can be customized with a variety of textures, solving the shortcomings of traditional sunshades that have a monotonous appearance and cannot match high-end interiors, thus improving the aesthetics and harmony of the entire vehicle interior.

[0097] Example 4 This embodiment provides an automotive sunroof assembly, including a sunroof frame, a glass panel, and the automotive sunroof reflective, heat-insulating, and anti-static sunshade curtain described in any of the above embodiments one, two, and three.

[0098] Furthermore, a sliding guide rail is provided inside the sunroof frame, and the two sides of the sunshade are fitted and engaged in the sliding guide rail. It can move back and forth along the guide rail inside the glass panel, opening or closing. When the sunshade is fully opened, it can completely cover the inner side of the glass panel, achieving efficient reflection, heat insulation, light blocking, and anti-static protection for the sunroof area.

[0099] This sunroof assembly is easy to assemble and highly adaptable. The sunshade structure can be selected according to the vehicle model, sunroof size, and cost budget. It can significantly improve the light and heat environment inside the vehicle, reduce static electricity adsorption and cleaning costs, improve driving comfort and overall vehicle quality, and has good prospects for industrial application.

[0100] The above are merely preferred embodiments of the present invention and are not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A reflective, heat-insulating, and anti-static sunshade for car sunroofs, characterized in that: From top to bottom, it consists of layers of warp-knitted fabric, composite film, and bottom reflective layer; The composite film is formed by combining a black light-blocking film and a silver reflective film. The bottom reflective layer is a PET reflective film or a polyester woven reflective fabric; The composite film, PET reflective film, and polyester woven reflective fabric all contain antistatic agents, which are quaternary ammonium salt antistatic agents.

2. The car sunroof reflective, heat-insulating, and anti-static sunshade curtain according to claim 1, characterized in that, The composite adhesive film is sandwiched between the warp-knitted fabric and the underlying reflective layer and directly bonded and fixed.

3. The car sunroof reflective, heat-insulating, and anti-static sunshade curtain according to claim 1, characterized in that, The thickness of the composite film is 0.15mm to 0.2mm.

4. The car sunroof reflective, heat-insulating, and anti-static sunshade curtain according to claim 1, characterized in that, The black light-blocking film is made of EVA material, and the silver reflective film is made of PET material.

5. The car sunroof reflective, heat-insulating, and anti-static sunshade curtain according to claim 1, characterized in that, The PET reflective film is a PET reflective base film with a microprism structure formed on its surface; The polyester woven reflective fabric is a reflective fabric made by coating an aluminum reflective layer on the surface of a polyester woven substrate.

6. A reflective, heat-insulating, and anti-static sunshade for car sunroofs, characterized in that: include: Warp-knitted fabric, black TPU layer, and reflective bottom layer; The upper and lower surfaces of the black TPU layer are provided with PUR adhesive layers, and the black TPU layer is bonded to the warp-knitted fabric and the bottom reflective layer respectively through the PUR adhesive layers; The bottom reflective layer is a PET reflective film or a polyester woven reflective fabric; The black TPU layer, PET reflective film, and polyester woven reflective fabric all contain antistatic agents, which are quaternary ammonium salt antistatic agents.

7. The car sunroof reflective, heat-insulating, and anti-static sunshade curtain according to claim 6, characterized in that, The PUR adhesive layer is formed by curing a hot-melt PUR adhesive, and the thickness of the PUR adhesive layer is 0.05mm to 0.10mm.

8. The car sunroof reflective, heat-insulating, and anti-static sunshade curtain according to claim 6, characterized in that, The black TPU layer is a thermoplastic polyurethane layer with added carbon black opacifier, and its thickness is 0.15mm to 0.30mm.

9. The car sunroof reflective, heat-insulating, and anti-static sunshade curtain according to claim 6, characterized in that, The antistatic agent is a quaternary ammonium salt antistatic agent, and it is uniformly dispersed inside the black TPU layer, PET reflective film and polyester woven reflective fabric.

10. A car sunroof assembly, characterized in that, include: The sunroof body and the automotive sunroof reflective, heat-insulating, and antistatic sunshade curtain as described in any one of claims 1-9; the sunshade curtain is installed on the inner side of the sunroof body and is used to reflect light, insulate heat, and provide antistatic protection for the sunroof area.

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