A smart dimming laminated vacuum composite roof glass structure and its preparation method

Abstract

This invention provides an intelligent dimming laminated vacuum composite roof glass structure and its manufacturing method, comprising an outer tempered or semi-tempered glass, a film layer, an EC-coated glass, an edge sealing layer, and an inner vacuum glass layer, stacked sequentially from the outside of the roof to the inside of the vehicle. The EC-coated glass and the inner vacuum glass are edge-sealed by the edge sealing layer to form an EC-coated insulated glass structure. Then, a getter is activated by laser evaporation to adsorb air from the insulated glass structure, forming an EC-coated vacuum glass structure. The film layer is then laminated and fixed to the outer tempered or semi-tempered glass to form a laminated vacuum composite structure. Multiple vacuum support pillars are provided on the side of the inner vacuum glass facing the EC-coated glass to form and maintain the vacuum cavity. This invention uses vacuum glass to isolate external heat conduction, combined with the active modulation of visible light and infrared radiation by the EC-coated glass, to achieve intelligent temperature regulation, significantly improving driving comfort.

Description

Technical Field

[0001] This invention relates to the field of automotive smart dimming glass technology, specifically to a smart dimming laminated vacuum composite roof glass structure and its preparation method. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the application of roof glass structures (i.e., sunroofs / panoramic sunroofs) in automobiles is becoming increasingly widespread, effectively improving the sense of space and passenger experience. However, large sunroofs / panoramic sunroofs bring serious problems of interior sun exposure in summer, affecting passenger comfort.

[0003] To address these issues, intelligent dimming glass for automobiles has emerged. Currently, mainstream intelligent dimming sunroofs / panoramas on the market primarily use laminated glass structures with an organic dimming film inside. However, existing organic dimming films can only regulate visible light and cannot effectively block infrared rays from entering the vehicle. This allows solar heat to still directly penetrate the vehicle through the sunroof / panora, causing the interior temperature to rise rapidly.

[0004] To address the issue of infrared transmission, existing technologies have proposed all-solid-state inorganic electrochromic (EC) laminated glass. This technology can simultaneously modulate visible light and infrared radiation, effectively blocking direct penetration of sunlight's infrared rays into the vehicle interior. However, all-solid-state inorganic EC laminated glass still has the following drawbacks in practical applications: In summer, the outer surface of the sunroof / sunroof can reach temperatures of 60°C or even above 90°C under sunlight. This heat is conducted through the laminated glass, significantly raising the temperature of the inner surface of the sunroof / sunroof, resulting in secondary heat radiation from the heated surfaces inside the roof. This secondary heat radiation causes a noticeable burning sensation on the heads of the driver and passengers, severely impacting ride comfort.

[0005] To address the aforementioned issue of secondary heat radiation, the traditional solution is to install sunshades or partitions above the head of the vehicle to block secondary heat radiation from the interior surfaces of the roof. However, this solution not only occupies overhead space, affecting the feeling of spaciousness inside the vehicle, but also fails to fundamentally solve the heat radiation problem, resulting in a poor user experience.

[0006] Therefore, how to effectively solve the problem of secondary heat radiation from automotive intelligent dimming sunroofs / canopies, while maintaining the function of using infrared heating in winter, has become an urgent technical problem to be solved in this field. Summary of the Invention

[0007] The purpose of this invention is to overcome the shortcomings of the prior art and provide an intelligent dimming laminated vacuum composite sunroof with a laminated vacuum composite structure that can effectively block secondary heat radiation inside the roof of a vehicle, while also having the functions of heat insulation in summer and heat permeability in winter, as well as its preparation method.

[0008] To achieve the above objectives, the present invention adopts the following technical solution: A smart dimming laminated vacuum composite sunroof includes an outer layer of tempered or semi-tempered glass, a film layer, an all-solid-state inorganic electrochromic coated glass, an edge sealing layer, and an inner layer of vacuum glass, stacked sequentially from the exterior of the vehicle roof to the interior. The all-solid-state inorganic electrochromic coated glass, also known as EC coated glass, has its EC coated surface facing inward and is edge-sealed with the inner layer of vacuum glass through the edge sealing layer, forming an EC coated insulated glass structure. Within the EC coated insulated glass structure, a getter is activated by laser evaporation to adsorb air, forming an EC coated vacuum glass structure. The EC coated vacuum glass structure is laminated and fixed to the outer layer of tempered or semi-tempered glass through the film layer, forming a laminated vacuum composite structure. Multiple vacuum support columns are provided on the side of the inner layer of vacuum glass facing the all-solid-state inorganic electrochromic coated glass to form and maintain a vacuum cavity between the inner layer of vacuum glass and the all-solid-state inorganic electrochromic coated glass.

[0009] Furthermore, the outer tempered or semi-tempered glass, the all-solid-state inorganic electrochromic coated glass, and the inner vacuum glass are hyperbolic tempered or semi-tempered glass with the same curved surface formed by a paired hot bending process.

[0010] Furthermore, the outer tempered or semi-tempered glass has a thickness of 2-5 mm; the film layer has a thickness of 0.38-1.52 mm; the all-solid-state inorganic electrochromic coated glass has a thickness of 2-5 mm; and the inner vacuum glass has a thickness of 2-5 mm.

[0011] Furthermore, the sealing edge width of the edge sealing layer is 0.3~2cm, and the height is 0.3~0.5mm.

[0012] Furthermore, the diameter of the support column is 0.2~2mm, the height is 0.3~0.5mm, and the spacing between adjacent support columns is 0.5~5cm.

[0013] Furthermore, the EC-coated insulating glass structure is pre-installed with, but is not limited to, a metal alloy getter. The metal alloy getter is activated by laser local evaporation and is used to absorb air in the hollow cavity to form the required vacuum level.

[0014] Furthermore, the film layer is made of, but is not limited to, a film made of PVB, SGP, or PO materials.

[0015] A method for fabricating an intelligent dimming laminated vacuum composite sunroof, used to prepare the aforementioned intelligent dimming laminated vacuum composite roof glass structure, the method comprising the following steps: S1. The outer glass, the all-solid inorganic electrochromic coated glass, and the inner vacuum glass are formed into hyperboloid glass with the same curved surface by a paired hot bending process. S2. Multiple vacuum support columns are arranged on the side of the inner vacuum glass facing the all-solid inorganic electrochromic coating glass. S3. The all-solid-state inorganic electrochromic coated glass and the inner vacuum glass are sealed with an edge sealing layer to form a hollow structure. S4. A getter is pre-set in the hollow structure, and the getter is activated by laser evaporation to adsorb gas and form a vacuum cavity, thus obtaining an EC coated vacuum glass structure. S5. The EC coated vacuum glass structure is fixed to the outer glass layer by laminating the film layer to form a laminated vacuum composite roof glass structure.

[0016] Furthermore, the encapsulation temperature range in step S3 is 150°C to 400°C, and the bonding temperature range in step S5 is 120°C to 150°C.

[0017] Furthermore, in step S4, the getter is activated by laser-guided local heating and vaporization.

[0018] As can be seen from the above technical solutions, compared with the prior art, the beneficial effects of the present invention are: 1. This invention effectively blocks the conduction of external heat from the roof to the interior of the vehicle through the vacuum insulation layer of the inner vacuum glass. Even if the outer surface temperature of the sunroof / skylight reaches 60~100°C, the inner surface of the sunroof / skylight can still maintain a room temperature, eliminating secondary heat radiation from the heating surface inside the roof. The driver and passengers no longer feel a burning sensation on their heads, eliminating the need for additional sunshade curtains and improving the utilization rate of the head space. 2. This invention uses all-solid-state inorganic EC coated glass, which can simultaneously adjust the transmittance of visible light and infrared rays. In summer, it can effectively block infrared rays from directly entering the vehicle, while in winter, it can allow infrared rays to pass through to achieve the function of sunbathing and heating, thus achieving comfort in all seasons. 3. This invention maintains the transparency and aesthetics of the sunroof / skylight while ensuring heat insulation performance, thereby enhancing the sense of openness and comfort of the vehicle interior. 4. This invention proposes a process flow of high-temperature hollow encapsulation, laser activation of the getter, and low-temperature lamination. Through a paired hot bending process, the curvature of the three glass layers is ensured to be consistent, providing a structural foundation for precision encapsulation. Laser-guided point activation of the getter avoids thermal damage to the EC coating layer, vacuum support pillars, and edge sealing layer caused by overall high-temperature heating. The lamination process is carried out within a temperature range of 120°C to 150°C, protecting the integrity of the vacuum cavity and the electrochromic properties of the EC coating. This process route effectively avoids product defects caused by temperature mismatch in traditional processes, is suitable for mass automated production, and has good industrialization prospects. Attached Figure Description

[0019] Figure 1 This is an exploded structural diagram of the intelligent dimming laminated vacuum composite skylight / canopy and its preparation method of the present invention; Figure 2 This is a schematic diagram of the combined structure of the intelligent dimming laminated vacuum composite skylight / canopy and its preparation method of the present invention; In the diagram: 1. Outer tempered or semi-tempered glass; 2. Film layer; 3. All-solid-state inorganic electrochromic coated glass (EC coated glass); 4. Edge sealing layer; 5. Inner vacuum glass. Detailed Implementation

[0020] A preferred embodiment of the present invention will now be described in detail with reference to the accompanying drawings. Example 1

[0021] like Figure 1 and Figure 2 As shown, this embodiment provides a smart dimming laminated vacuum composite roof glass structure, which includes a five-layer structure stacked sequentially from the outside of the roof to the inside of the vehicle: an outer tempered or semi-tempered glass 1, a film layer 2, an all-solid inorganic electrochromic coated glass (hereinafter referred to as EC coated glass) 3, an edge sealing layer 4, and an inner vacuum glass 5.

[0022] The outer tempered or semi-tempered glass 1, EC-coated glass 3, and inner vacuum glass 5 are three pieces of hyperbolic tempered or semi-tempered glass with identical curved surfaces, formed through a paired hot bending process. In the specific manufacturing process, the three flat glass pieces are stacked and placed in a high-temperature furnace for heating and softening. They are then pressed together using a mold to synchronously form the desired hyperbolic shape, ensuring that the curvature of the three glass pieces is completely consistent, providing a structural foundation for subsequent precision packaging.

[0023] The EC-coated glass 3 is formed by depositing an all-solid-state inorganic electrochromic functional layer onto the concave surface of the intermediate layer glass after pairing and hot bending, using a magnetron sputtering process. This EC-coated glass 3 can reversibly adjust the transmittance of visible light and infrared rays under the action of an external electric field, thereby achieving active control of direct solar radiation.

[0024] The inner vacuum glass 5 is prepared by screen printing and high-temperature baking on the side of the bottom glass facing the EC-coated glass 3 after the bottom glass has been paired and hot-bent. In this embodiment, the diameter of the support pillars is 0.1~2mm, the height is 0.3~0.5mm, and the spacing between adjacent vacuum support pillars is 0.5~5cm. These vacuum support pillars are used to support the inner and outer glass layers after the vacuum cavity is formed, resisting atmospheric pressure and maintaining the stability of the vacuum cavity.

[0025] The EC-coated glass 3 and the inner vacuum glass 5 are edge-sealed by an edge sealing layer 4. Specifically, after aligning and stacking the two, a sealing material is applied to the edge area, and edge hollow sealing is performed at a temperature range of 150°C to 400°C to form an EC-coated hollow glass structure. In this embodiment, the sealing edge width of the edge sealing layer 4 is 0.1~2cm, and the height is 0.3~0.5mm.

[0026] Subsequently, the encapsulated EC-coated insulated glass structure is laminated with the outer tempered or semi-tempered glass 1 via the film layer 2. Specifically, the film layer 2 is laid on the upper surface of the EC-coated insulated glass structure, and then the outer tempered or semi-tempered glass 1 is stacked on top. The lamination process is carried out at a temperature range of 120°C to 150°C to form a laminated insulated composite structure. In this embodiment, the thickness of the outer tempered or semi-tempered glass 1 is 2-5 mm, the thickness of the film layer 2 is 0.38-1.52 mm, and the material of the film layer 2 can be selected from PVB, SGP, or PO; the thickness of the EC-coated glass 3 is 2-5 mm; and the thickness of the inner vacuum glass 5 is 2-5 mm.

[0027] Finally, the laminated hollow composite structure undergoes laser evaporation to activate the getter and vacuum process. A getter is pre-placed within the hollow cavity between the EC coated glass 3 and the inner vacuum glass 5. The raw materials for preparing the getter are selected from one or more combinations of the following metals and alloys: Zirconium (Zr): As a base material for non-evaporative getters, it has excellent getter properties and chemical stability, and can effectively adsorb reactive gases such as hydrogen, oxygen, nitrogen, and carbon monoxide.

[0028] Titanium (Ti): It is often alloyed with metals such as zirconium and vanadium to improve gas intake efficiency and optimize gas intake performance at different operating temperatures.

[0029] Vanadium (V): As an alloying element, it can be used in combination with metals such as zirconium and titanium to adjust the activation temperature and getter characteristics of getters.

[0030] Zirconium-aluminum (Zr-Al) alloy: a commonly used non-evaporative getter material, which is usually thermally activated at a temperature of 400°C to 600°C. After activation, it can effectively adsorb gases such as nitrogen, oxygen, carbon dioxide, and water vapor, and is widely used in ultra-high vacuum systems and high-performance vacuum glass.

[0031] Zirconium-vanadium-iron (Zr-V-Fe) alloys: As an alternative, these alloys have a low activation temperature (as low as 200°C to 400°C), making them suitable for heat-sensitive structures or processes requiring low-temperature activation.

[0032] The getter can be in the form of sheets, filaments, mesh, or coatings, and is physically fixed to the edge area of ​​the inner vacuum glass 5 facing the EC coated glass 3 or the gap of the support column to ensure maximum contact area with the gas inside the vacuum cavity. After completing the laminated hollow composite structure, the getter is thermally evaporated and activated by laser local heating. Laser heating removes the oxide layer on the surface of the getter, exposing active metal atoms, thereby activating its gettering ability to continuously absorb residual gas in the vacuum cavity, forming and maintaining a high vacuum state, and finally forming a laminated vacuum composite structure of all-solid-state inorganic EC coated glass smart dimming roof glass.

[0033] This embodiment employs a process flow of first high-temperature hollow encapsulation, then laser evaporation to activate the getter, and finally low-temperature lamination to form a vacuum-laminated composite structure. This effectively avoids product defects caused by temperature mismatch in traditional processes, significantly improves the production yield, and is suitable for mass automated production.

[0034] Working principle and technical effects The working principle of the laminated vacuum composite intelligent dimming roof glass structure provided in this embodiment is as follows: In hot summer conditions, the outer surface of the sunroof / sunroof can reach temperatures of 60-100°C under direct sunlight. At this temperature, some of the heat absorbed by the outer tempered or semi-tempered glass 1 is dissipated through convection, while some is conducted into the vehicle interior. However, due to the presence of the inner vacuum glass 5, its vacuum cavity has extremely low thermal conductivity, effectively blocking heat conduction from the outer layer to the interior surface. Simultaneously, the EC-coated glass 3 can be adjusted to a tinted state as needed, blocking infrared rays from directly penetrating the vehicle interior. Therefore, even with extremely high temperatures on the outer surface of the sunroof / sunroof, the inner surface (i.e., the interior side of the inner vacuum glass 5) remains close to room temperature, completely eliminating the secondary heat radiation problem of the internal heating surface in traditional laminated glass structures. Drivers and passengers no longer experience a burning sensation on their heads, eliminating the need for additional sunshades and improving the sense of openness and comfort within the vehicle.

[0035] In winter, the EC coated glass 3 can be adjusted to a faded state, allowing infrared rays from sunlight to enter the vehicle through the sunroof / skylight, enabling passengers to enjoy the warmth of sunlight and achieving intelligent adjustment for both winter and summer comfort.

[0036] The performance of the skylight / canopy structure prototype prepared in this embodiment was tested, and the results are as follows: Total solar transmittance (TTS): 7.1% in the tinted dark state and 49.9% in the faded transparent state; Visible light transmittance: less than 0.1% in the tinted dark state and 64% in the faded transparent state; Thermal insulation performance: When the outer surface is heated to 80°C, the inner surface temperature remains below 28°C for 1 hour (tested at room temperature of 25°C). Energy consumption simulation: Compared to ordinary laminated glass skylights / canopies, air conditioning energy consumption is reduced by about 30% in summer.

[0037] Test results show that the sunroof / canopy in this embodiment can effectively block solar heat radiation and eliminate secondary heat radiation in summer, while allowing infrared rays to pass through in winter to achieve heating function, significantly improving ride comfort and effectively extending the driving range of new energy vehicles.

[0038] Comparative Example 1 To verify the technical effect of the present invention, Comparative Example 1 was set up: a traditional laminated structure was adopted, without a vacuum layer, consisting only of an outer glass layer, a film layer and EC coated glass.

[0039] Test results show that when the outer surface is heated to 80°C, the inner surface temperature rises rapidly to 60°C within 15 minutes, generating significant secondary heat radiation. Passengers experience a burning sensation on their heads, indicating that the heat insulation effect is significantly inferior to that of the embodiment of the present invention.

[0040] Comparative Example 2 Comparative Example 2: Using laminated hollow composite glass (equivalent to the internal getter not being activated by laser evaporation), a laminated hollow composite structure of the same size is formed only by mechanical edge sealing.

[0041] Test results showed that when the outer surface was heated to 80°C, the inner surface temperature rose to 52°C within one hour, generating significant secondary heat radiation, and passengers still experienced a burning sensation on their heads. The heat insulation effect was significantly inferior to that of the embodiments of the present invention, indicating that laser evaporation to activate the getter and form a vacuum is crucial.

[0042] The above-described embodiments are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. An intelligent dimming laminated vacuum composite roof glass structure, characterized in that, The outer layer of tempered or semi-tempered glass (1), the film layer (2), the all-solid-state inorganic electrochromic coated glass (3), the edge sealing layer (4) and the inner layer of vacuum glass (5) are sequentially stacked from the outside of the roof to the inside of the vehicle. The all-solid-state inorganic electrochromic coated glass (3) is an EC coated glass, and the EC coated surface faces inward and is edge-sealed with the inner layer of vacuum glass (5) through the edge sealing layer (4) to form an EC coated hollow glass structure. The EC coated hollow glass structure is activated by laser evaporation to activate the getter to adsorb air to form an EC coated vacuum glass structure. The EC coated vacuum glass structure is fixed by the film layer (2) and the outer layer of tempered or semi-tempered glass (1) to form a laminated vacuum composite structure. The inner layer of vacuum glass (5) is provided with a plurality of vacuum support columns on the side facing the all-solid-state inorganic electrochromic coated glass (3) to form and maintain a vacuum cavity between the inner layer of vacuum glass (5) and the all-solid-state inorganic electrochromic coated glass (3).

2. The smart dimming laminated vacuum composite roof glass structure according to claim 1, wherein, The outer layer of tempered or semi-tempered glass (1), the all-solid-state inorganic electrochromic coated glass (3) and the inner layer of vacuum glass (5) are double-curved tempered or semi-tempered glass with the same curvature formed by a matching heat bending process.

3. The smart dimming laminated vacuum composite roof glass structure according to claim 2, wherein, The thickness of the outer layer of tempered or semi-tempered glass (1) is 2-5mm; the thickness of the film layer (2) is 0.38-1.52mm; the thickness of the all-solid-state inorganic electrochromic coated glass (3) is 2-5mm; and the thickness of the inner layer of vacuum glass (5) is 2-5mm.

4. The smart tinting laminated vacuum co-extruded roof glass structure of claim 1, wherein, The sealing edge width of the edge sealing layer (4) is 0.3-2cm, and the height is 0.3-0.5mm. 5.The smart dimming laminated vacuum laminated roof glass structure according to claim 1, wherein, The diameter of the support column is 0.2-2mm, the height is 0.3-0.5mm, and the distribution spacing between adjacent support columns is 0.5-5cm.

6. The smart tinting laminated vacuum co-extruded roof glass structure of claim 1, wherein, The EC coated hollow glass structure is pre-provided with a metal alloy getter which is activated by laser local evaporation to absorb air in the hollow cavity to form the required vacuum degree.

7. The smart tinting laminated vacuum co-extruded roof glass structure of claim 1, wherein, The material of the film layer (2) is one of PVB, SGP or PO film.

8. A method for preparing the smart light-adjustable laminated vacuum composite roof glass structure according to any one of claims 1-7, wherein, The preparation method comprises the following steps: S1, forming the outer layer of glass (1), the all-solid-state inorganic electrochromic coated glass (3) and the inner layer of vacuum glass (5) into double-curved glass with the same curvature by a matching heat bending process; S2, arranging a plurality of vacuum support columns on the side of the inner layer of vacuum glass (5) facing the all-solid-state inorganic electrochromic coated glass (3); S3, sealing the all-solid-state inorganic electrochromic coated glass (3) and the inner layer of vacuum glass (5) through the edge sealing layer (4) to form a hollow structure; S4, pre-providing a getter in the hollow structure, activating the getter by laser to adsorb gas to form a vacuum cavity, and obtaining an EC coated vacuum glass structure; S5, laminating the EC coated vacuum glass structure with the outer layer of glass (1) through the film layer (2) to form a laminated vacuum composite roof glass structure.

9. The method of claim 8, wherein the method further comprises: The encapsulation temperature range in step S3 is 150°C to 400°C, and the bonding temperature range in step S5 is 120°C to 150°C.

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