Method for manufacturing a 3D-shaped display glass

Abstract

Method for manufacturing a 3D-shaped display glass (1), wherein the 3D-shaped display glass (1) has an integrated sensor (3), characterized in that A) a polymeric plate (5) is provided as a support, wherein the polymeric plate (5) is transparent, B) the polymeric plate (5) is coated on at least one side with a first sensor layer (3), wherein the first sensor layer (3) is applied to the polymeric plate (5) by means of a carrier film and / or by means of screen printing, so that a sensor-coated polymeric plate (7) is obtained, C) the sensor-coated polymer plate (7) is heated, D) the heated sensor-coated polymer plate (7) is placed in a mold (9), wherein the sensor-coated polymer plate (7) is arranged such that one side of the sensor-coated polymer plate (7) facing away from the first sensor layer (3) is at least partially opposite a carrier film (11) for applying a color layer (13) and / or a second sensor layer (15) in the mold (9), E) the sensor-coated polymer plate (7) is pressed in the mold (9) under a specific pressure (17) and at a specific temperature (19), the color layer (13) and / or the second sensor layer (15) being applied to the side of the sensor-coated polymer plate (5) facing away from the first sensor layer (3), the coatings being bonded together, and the sensor-coated polymer plate (7) being formed into a composite material (21), and F) the composite material (21) is removed from the mold (9) so that the 3D-shaped display glass (1), in particular an operable display glass, is obtained.

Description

[0001] The invention relates to a method for manufacturing a 3D-shaped display glass.

[0002] For mobile electronic devices used in everyday life, such as tablets or smartphones, lightweight and durable housings are required that can be manufactured at low cost. A range of different thermoplastic composites, especially fiber-reinforced composites, are used as materials. These composites can be molded into the desired housing using a mold. To save weight, the housing should be as thin as possible, while still possessing the necessary stability for such devices. The production of thin-walled components from fiber-reinforced thermoplastic material, particularly organosheets, for housings of mobile electronic devices is known from the prior art.

[0003] Composite molded parts consisting of a film and a plastic body, particularly a fiber-reinforced composite plastic, have been known for some time. The plastic bodies can be coated with a colored layer and / or a layer with tactile properties. Such composite molded parts are becoming increasingly important in communication devices and vehicle manufacturing. Fiber-reinforced composite plastics are versatile and flexible in their applications. By selecting the appropriate fiber, material, and / or structure, their mechanical properties can be optimally adapted to the specific requirements of the component, especially the stresses it will be subjected to. This allows for thinner and / or lighter components compared to conventional components, while maintaining the same load-bearing capacity.

[0004] German patent application DE 10 2016 112 505 A1 discloses a transfer film comprising a carrier film and a transfer layer, wherein the transfer film is intended for transferring the transfer layer onto a three-dimensional component. The transfer layer can be configured as a color layer or as a protective layer. The transfer film is applied to a component using an insert molding process.

[0005] German patent application DE 10 2016 118 259 A1 discloses a method for processing films, as well as a feed device and an injection mold. In the method for processing film webs, at least two film webs arranged side by side in a direction substantially perpendicular to the feed direction are provided. The side by side film webs are fed into the injection mold and aligned, whereby transferable layers are applied to plastic parts, for example, to housing shells of portable devices, by means of the carrier film. Using in-mold decoration (IMD) technology, a carrier film is inserted into a cavity of a mold and back-injected with a flowable filler medium. After back-injection, the carrier film can be peeled off the layer transferred onto the solidified filler medium.

[0006] German patent application DE 10 2015 109 597 A1 discloses a method for producing a molded plastic body, wherein a base body based on at least one fiber-reinforced plastic and a decorative film are provided, the base body is heated, and the base body is joined with the decorative film in a mold. This results in a molded plastic body comprising a base body made of a fiber-reinforced plastic and a decorative film which forms at least one surface area of ​​the molded plastic body.

[0007] German patent DE 10 2017 101 595 B3 discloses a transfer film and a method for producing the transfer film, as well as a method for producing an injection-molded article decorated with a transfer layer of a transfer film. The transfer film comprises a carrier film and a transfer layer arranged on the carrier film and removable from the carrier film.

[0008] German patent application DE 10 2013 114 276 A1 discloses a method for manufacturing a plastic molded part, comprising the steps of: a) providing a first decorative film which has a partial opaque coating; b) introducing a decorative element into the first decorative film by processing it with a processing tool; c) providing a second decorative film; d) inserting the decorative films into an injection mold with a first and second mold half, which together form a cavity for molding the plastic molded part, wherein the first decorative film is applied to a first wall of the cavity and the second decorative film is applied to a second wall of the cavity opposite the first wall; e) back-injecting the decorative films with a plastic compound, such that the first decorative film forms a first surface and the second decorative film forms a second surface opposite the first surface of the plastic molded part.

[0009] International patent application WO2008 / 003621A1 discloses a three-dimensionally deformed foil element producible by isostatic high-pressure deformation, a method for producing the three-dimensionally deformed foil element according to the invention, and the use of the three-dimensionally deformed foil element according to the invention for forming display elements such as a speedometer dial for land, water, and air vehicles, for forming seat belt covers or warning bezels in land, water, and air vehicles and warning bezels in buildings, and for forming housing elements for mobile and stationary electronic devices and for forming a keyboard.

[0010] The international patent application WO 2017 / 093 066 A1 discloses a film, a method for producing a film, the use of a film for application to a target substrate and a method for producing an electrical functional element.The film comprises a carrier substrate, an adhesion promoter layer for applying the film to a target substrate, and an electrically conductive layer, wherein the electrically conductive layer forms an electrical functional structure in a functional area, wherein the electrically conductive layer forms a contacting structure for contacting the electrical functional structure in a contacting area, and wherein the adhesion promoter layer, when viewed perpendicular to a plane spanned by the carrier substrate, does not cover the contacting area in certain areas, or wherein the adhesion promoter layer, when viewed perpendicular to a plane spanned by the carrier substrate, is applied over the entire surface.

[0011] Japanese patent application JP 2013-246741A discloses a three-dimensional display or touch panel with a curved surface, featuring a sensor without faulty functionality, a highly transparent touch surface, and an electronic device housing incorporating the touch panel. A capacitive touch panel is a molded part with a three-dimensionally curved surface, produced by heating and softening and then drawing a laminate comprising a main electrode layer. This laminate, on the surface of a base material plate, includes a plurality of main electrode areas with a strain percentage of 10% or less and a visible light transmittance of 90% or more.

[0012] In particular, the laminate further comprises an auxiliary electrode layer, which includes a multitude of auxiliary electrode regions with a strain percentage of 70% or more and a visible light transmittance of 75 to 85% around the perimeter of the three-dimensionally curved surface. The auxiliary electrode regions of the auxiliary electrode layer are configured to overlap portions of the main electrode regions of the main electrode layer located at the periphery of the three-dimensionally curved surface. The auxiliary electrode layer and the main electrode layer are conductive in the overlapping sections.

[0013] However, the known methods for manufacturing a housing, especially for a mobile electronic device, do not allow the production of a 3D-shaped display glass, especially thin, transparent display glass, which has an integrated sensor.

[0014] The invention is therefore based on the objective of creating a method for producing a 3D-shaped display glass, without the aforementioned disadvantages occurring.

[0015] The problem is solved by creating the subject matter of the independent claim. Advantageous embodiments result from the dependent claims.

[0016] The problem is solved in particular by providing a method for manufacturing a 3D-shaped display glass, wherein the 3D-shaped display glass has an integrated sensor. The method is characterized in that A) a polymeric plate is provided as a support, wherein the polymeric plate is transparent, B) the polymeric plate is coated on at least one side with a first sensor layer, wherein the first sensor layer is applied to the polymeric plate by means of a carrier film and / or by means of screen printing, so that a sensor-coated polymeric plate is obtained, C) the sensor-coated polymer plate is heated, D) the heated sensor-coated polymer plate is placed in a mold, wherein the sensor-coated polymer plate is arranged such that one side of the sensor-coated polymer plate facing away from the first sensor layer is at least partially opposite a carrier film for applying a color layer and / or a second sensor layer in the mold, E) the sensor-coated polymer plate is pressed in the mold under a specific pressure and at a specific temperature, wherein the color layer and / or the second sensor layer is applied to the side of the sensor-coated polymer plate facing away from the first sensor layer, wherein the coatings are bonded together, and wherein the sensor-coated polymer plate is formed into a composite material, and F) the composite material is removed from the mold so that the 3D-shaped display glass, in particular an operable display glass, is obtained.

[0017] Preferably, in step C) the coated polymeric plate is heated to a temperature of 50 °C to 300 °C, preferably from 100 °C to 300 °C, or preferably from 50 °C to 200 °C.

[0018] Preferably, the coated polymer plate is heated outside the mold and / or inside the mold.

[0019] Preferably, the polymer plate is fixed in step B), in step C) and / or in step D) by means of a clamping device, in particular by means of a clamping frame, and / or by means of vacuum suction.

[0020] Preferably, the 3D-shaped display glass is formed in one piece, more preferably in one piece.

[0021] Preferably, the composite material and / or the 3D-shaped display glass is cooled completely or partially, preferably before removal from the mold, or preferably after removal from the mold.

[0022] The invention proposes a method for manufacturing a 3D-shaped display glass, in particular an operable display glass, which has an integrated sensor layer. Using a polymeric plate as a substrate, a first sensor layer is applied to the polymeric plate by means of a carrier film and / or screen printing. The sensor-coated polymeric plate, with the first sensor layer on it, is heated and placed in a mold, whereby the sensor-coated polymeric plate is transformed into a composite material in a pressing process. In the pressing process, a color layer and / or a second sensor layer are applied, according to requirements, in a single-stage process to one side of the sensor-coated polymeric plate facing away from the first sensor layer by means of a carrier film during the pressing process.

[0023] The process for manufacturing 3D-shaped display glass offers advantages compared to the state of the art. Advantageously, the process allows for the integration of a sensor into the 3D-shaped display glass. Advantageously, the 3D-shaped display glass is produced in a single-stage process. Advantageously, pressing a thermally activated, coated polymer sheet creates a low-stress display glass with high dimensional stability. Advantageously, a particularly lightweight display glass is obtained. Advantageously, a 3D-shaped display glass with a particularly thin layer is obtained, while maintaining the mechanical strength compared to conventional display glass. Advantageously, the process leads to cost savings. Advantageously, the process allows for the production of a 3D display glass with any desired geometry.Advantageously, the impact resistance of the 3D-shaped display glass is particularly high.

[0024] A 3D-shaped display glass is understood to be, in particular, a housing that is at least partially transparent and incorporates an integrated sensor. Similarly, a display is understood to be a component comprising the 3D-shaped display glass, which in particular includes a screen, especially an LED or OLED screen.

[0025] A polymeric sheet is understood to be, in particular, a transparent, and especially at least partially flexible, sheet. Preferably, the polymeric sheet is formed from at least one thermoplastic, preferably selected from the group consisting of polyolefins, vinyl polymers, polyacrylates, polyamides, polyurethanes, polyureas, polyimides, polyesters, polyethers, polystyrenes, polyhydantoins, polyphenylene oxides, polyarylene sulfides, polysulfones, polycarbonates, and polymethyl methacrylate.

[0026] Preferably, the color layer and / or the sensor layer are applied to the polymer plate in specific areas. Preferably, the color layer is applied to an edge of the polymer plate. Preferably, the sensor layer is applied to an inner area of ​​the polymer plate, particularly an area where a screen is intended to be mounted.

[0027] Preferably, the polymer plate has an adhesion promoter layer so that the color layer and / or the sensor layer adhere better to the polymer plate. Preferably, the adhesion promoter layer is made of acrylates, polyester resins, alkyl resins, amino resins, amido resins, or phenolic resins. Preferably, the adhesion promoter layer is transparent.

[0028] A sensor layer is understood to be, in particular, a layer that incorporates a sensor. Preferably, the sensor is a touch sensor or a sensor for environmental detection.

[0029] An integrated sensor is understood to be, in particular, a sensor layer applied in or to a polymeric plate, especially one that is shaped.

[0030] Forming or shaping refers in particular to the shaping of a polymeric plate, especially a three-dimensional shaping of a polymeric plate, which corresponds in particular to the three-dimensional shape of the 3D-shaped display glass to be obtained.

[0031] A carrier film is understood to be, in particular, a film with a color layer and / or a sensor layer, wherein the color layer and / or the sensor layer are transferable to a carrier, in particular a color layer and / or sensor layer applied to the carrier film, which can be applied to the surface of a polymeric plate by means of the carrier film.

[0032] Preferably, the color layer and / or the sensor layer are applied to the polymeric plate using an in-mold decoration (IMD) process with an IMD film as a carrier film, wherein the carrier film, in particular a transparent carrier film, comprises a color layer and / or a sensor layer. After application of the color layer and / or the sensor layer, the carrier film is removed. Alternatively, the color layer and / or the sensor layer are preferably applied to the polymeric plate using a film-insert-molding (FIM) process, wherein the carrier film, in particular a transparent carrier film, comprises a color layer and / or a sensor layer. After application of the color layer and / or the sensor layer, the carrier film remains on the polymeric plate and is subsequently bonded to the polymeric plate.

[0033] Preferably, the carrier film is a PET, PEN, OPP, BOPP, PE or cellulose acetate film.

[0034] Preferably, the carrier film has a layer thickness of 5 µm to 250 µm, preferably of 10 µm to 100 µm.

[0035] Preferably, the carrier film has a release layer on one side facing the color layer and / or the sensor layer, in particular made of a wax or a silicone.

[0036] A color layer is understood to be, in particular, a layer for coloring and / or decorating a substrate, especially a polymeric plate.

[0037] Preferably, the color layer is based on melanin, polyurethane, polyacrylate, polyol, isocyanate and / or polyvinyl chloride as a carrier material, wherein color particles are preferably distributed in the carrier material.

[0038] Preferably, the color layer and / or the sensor layer has a layer thickness of 0.2 µm to 250 µm, preferably from 0.2 µm to 100 µm, preferably from 0.2 µm to 50 µm, preferably from 0.2 µm to 100 µm, preferably from 1 µm to 250 µm, preferably from 1 µm to 100 µm, preferably from 1 µm to 50 µm, or preferably from 1 µm to 10 µm.

[0039] According to a further development of the invention, it is provided that the material composite is hardened after step E) or the 3D-shaped display glass is hardened after step F), preferably by heating and / or UV radiation.

[0040] According to a further development of the invention, at least one screw boss and / or at least one stiffener are molded and / or injection-molded onto the composite material and / or the 3D-shaped display glass during and / or after step E). Preferably, a frame is molded and / or injection-molded onto the composite material and / or the 3D-shaped display glass during and / or after step E), particularly at an edge of the composite material and / or the 3D-shaped display glass, preferably made of a polycarbonate matrix with glass and / or carbon fibers. Preferably, the at least one screw boss and / or the at least one stiffener are molded and / or injection-molded onto the edge region of the composite material and / or the 3D-shaped display glass, which is reinforced with glass fiber-reinforced material.

[0041] Preferably, during and / or after step E), a color layer and / or a decorative film are applied, at least in certain areas, to the composite material and / or the 3D-shaped display glass. Preferably, the color layer and / or the decorative film are pressed in step E) under a specific pressure and temperature so that the color layer and / or the decorative film are bonded to the composite material.

[0042] According to a further development of the invention, it is provided that a bonding layer and / or a color layer is applied at least partially to the side of the polymeric plate facing the first sensor layer and / or to a side of the first sensor layer facing the polymeric plate.

[0043] According to a further development of the invention, it is provided that the 3D-shaped display glass is coated with a scratch-resistant coating and / or an anti-fingerprint coating.

[0044] According to a further development of the invention, the polymeric plate is provided that at least partially composed of polyamide, polycarbonate, polymethyl methacrylate, polyvinyl chloride and / or polyester. Preferably, the edge region of the polymeric plate comprises glass fiber reinforced material, more preferably glass fiber reinforced polyamide, polycarbonate, polymethyl methacrylate, polyvinyl chloride and / or polyester.

[0045] According to a further development of the invention, the 3D-shaped display glass has a layer thickness of 750 µm to 7 mm, preferably 750 µm to 5 mm, or preferably 750 µm to 3 mm.

[0046] According to a further development of the invention, it is provided that during the forming process in step E) at least a surface structure and / or an embossing is introduced into the composite material in certain areas.

[0047] A surface structure and / or embossing refers in particular to a relief structure that is perceptible to the touch, and / or an optically effective microstructure, especially for anti-reflective coating of the display glass.

[0048] Preferably, the mold is tempered, preferably to a temperature of 50 °C to 300 °C, preferably 70 °C to 200 °C.

[0049] The invention will be explained in more detail below with reference to the drawings.

[0050] This shows: Fig. 1 a schematic representation of a method for manufacturing a 3D-shaped display glass in an exemplary embodiment, and Fig. 2 a schematic representation of the structure of the 3D-shaped display glass in an exemplary embodiment.

[0051] Fig. Figure 1 shows a schematic representation of a method for manufacturing a 3D-shaped display glass 1 in an exemplary embodiment, wherein the 3D-shaped display glass 1 has an integrated sensor 3. The method is characterized in that A) a polymeric plate 5 is provided as a substrate, wherein the polymeric plate 5 is transparent, B) the polymeric plate 5 is coated on one side at least partially with a first sensor layer 3, wherein the first sensor layer 3 is applied to the polymeric plate 5 by means of a carrier film and / or by means of screen printing, so that a sensor-coated polymeric plate 7 is obtained, C) the sensor-coated polymeric plate 7 is heated, D) the heated sensor-coated polymeric plate 7 is placed in a mold 9, wherein the sensor-coated polymeric plate 7 is arranged such thatthat one side of the sensor-coated polymer plate 7 facing away from the first sensor layer 3 is at least partially opposite a carrier film 11 for applying a color layer 13 and / or a second sensor layer 15 in the mold 9, E) the sensor-coated polymer plate 7 is pressed in the mold 9 under a specific pressure 17 and at a specific temperature 19, whereby the color layer 13 and / or the second sensor layer 15 is applied to the side of the sensor-coated polymer plate 7 facing away from the first sensor layer 3, whereby the coatings are bonded together, and wherein the sensor-coated polymer plate 7 is formed into a composite material 21, and F) the composite material 21 is removed from the mold 9, so that the 3D-formed display glass 1, in particular an operable display glass, is obtained.

[0052] Advantageously, the method enables the integration of a sensor into a display glass 1. Advantageously, the method yields a transparent display glass 1 with a particularly low weight. Advantageously, a 3D-shaped display glass 1 with a particularly low layer thickness is obtained, while maintaining the mechanical strength compared to conventional display glasses. Advantageously, the method leads to cost savings. Advantageously, the display glass 1 is obtained in a single-stage process.

[0053] In one embodiment of the invention, the composite material 21 is hardened according to step E) or the 3D-shaped display glass 1 is hardened according to step F), preferably by heating and / or UV rays 31.

[0054] In a further embodiment of the invention, during and / or after step E), at least one screw boss 23 and / or at least one stiffener 25 is molded and / or injection molded onto the composite material 21 and / or the 3D-shaped display glass 1.

[0055] In a further embodiment of the invention, a bonding layer and / or a color layer 27 is applied at least partially to the side of the polymeric plate 5 facing the first sensor layer 3 and / or to a side of the first sensor layer 3 facing the polymeric plate 5.

[0056] In a further embodiment of the invention, the 3D-shaped display glass 1 is coated with a scratch-resistant coating and / or an anti-fingerprint coating 29.

[0057] In a further embodiment of the invention, the polymeric plate 5 is formed at least partially from polyamide, polycarbonate, polymethyl methacrylate, polyvinyl chloride and / or polyester.

[0058] In a further embodiment of the invention, the 3D-shaped display glass 1 has a layer thickness of 750 µm to 7 mm.

[0059] In a further embodiment of the invention, during the forming process in step E), at least in certain areas a surface structure and / or an embossing is introduced into the composite material 21.

[0060] The device for carrying out the method comprises a forming tool 9, wherein the forming tool 9 in particular has a first tool half and at least one second tool half, between which a cavity is formed in the closed state, which is designed to be complementary to a shape of the 3D-shaped display glass 1 to be obtained. The heat introduced during heating and forming, in combination with pressure, bonds the first sensor layer, and the color layer and / or the second sensor layer to the polymer plate 5, so that a composite material 21 is obtained. The composite material 21 is obtained in particular in a single-stage process step.

[0061] In a further embodiment, the device has a cavity for introducing a plastic mass, which makes it possible to injection mold a screw boss 23 and / or a reinforcement 25 onto the composite material 21 and / or the 3D-shaped display glass 1.

[0062] The 3D-shaped display glass 1 can be used in particular in a display for a mobile electronic device, preferably for a tablet, a smartphone or a control unit, or for an electronic device arranged in a vehicle, in particular a head unit or an infotainment system.

[0063] Fig. Figure 2 shows a schematic representation of the structure of the 3D-shaped display glass 1 in an exemplary embodiment. Identical and functionally equivalent elements are marked with the same reference numerals, so reference is made to the preceding description.

[0064] The 3D-shaped display glass 1 comprises the polymeric plate 5, which is transparent. One side of the polymeric plate 5 is coated with the first sensor layer 3, and a color layer and / or a bonding layer 27, in particular an adhesion promoter, is applied at least partially between the polymeric plate 5 and the first sensor layer 3. The polymeric plate 5 has a color layer 13 and a second sensor layer 15 on the side facing away from the first sensor layer 3. A scratch-resistant coating and / or an anti-fingerprint coating 29 is applied to the color layer 13. The 3D-shaped display glass, in particular the sensor-coated polymeric plate 7, is arranged with the side coated with the first sensor layer 3 on a screen 33, in particular an LED or an OLED screen.

Claims

[1] Method for manufacturing a 3D-shaped display glass (1) wherein the 3D-shaped display glass (1) has an integrated sensor (3), characterized by , that A) a polymeric plate (5) is provided as a support, wherein the polymeric plate (5) is transparent, B) the polymeric plate (5) is coated on at least one side with a first sensor layer (3), wherein the first sensor layer (3) is applied to the polymeric plate (5) by means of a carrier film and / or by means of screen printing, so that a sensor-coated polymeric plate (7) is obtained, C) the sensor-coated polymer plate (7) is heated, D) the heated sensor-coated polymer plate (7) is placed in a mold (9), wherein the sensor-coated polymer plate (7) is arranged such that one side of the sensor-coated polymer plate (7) facing away from the first sensor layer (3) is at least partially opposite a carrier film (11) for applying a color layer (13) and / or a second sensor layer (15) in the mold (9), E) the sensor-coated polymer plate (7) is pressed in the mold (9) under a specific pressure (17) and at a specific temperature (19), the color layer (13) and / or the second sensor layer (15) being applied to the side of the sensor-coated polymer plate (5) facing away from the first sensor layer (3), the coatings being bonded together, and the sensor-coated polymer plate (7) being formed into a composite material (21), and F) the composite material (21) is removed from the mold (9) so that the 3D-shaped display glass (1), in particular an operable display glass, is obtained. [2] Method according to claim 1, wherein the composite material (21) is hardened according to step E) or the 3D-shaped display glass (1) is hardened according to step F), preferably by heating and / or UV radiation (31). [3] Method according to claim 1 or 2, wherein during and / or after step E) at least one screw boss (23) and / or at least one stiffener (25) is molded and / or injection molded onto the composite material (21) and / or the 3D-shaped display glass (1). [4] Method according to one of the preceding claims, wherein a bonding layer and / or a color layer (27) is applied at least partially to the side of the polymeric plate (5) facing the first sensor layer (3) and / or to a side of the first sensor layer (3) facing the polymeric plate (5). [5] Method according to one of the preceding claims, wherein the 3D-shaped display glass (1) is coated with a scratch-resistant coating and / or an anti-fingerprint coating (29). [6] Method according to any of the preceding claims, wherein the polymeric plate (5) is formed at least partially from polyamide, polycarbonate, polymethyl methacrylate, polyvinyl chloride and / or polyester. [7] Method according to any of the preceding claims, wherein the 3D-shaped display glass (1) has a layer thickness of 750 µm to 7 mm. [8] Method according to one of the preceding claims, wherein during the forming process in step E) at least a surface structure and / or an embossing is introduced into the composite material (21) in certain areas.

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