Manufacture of an illuminable laminated vehicle sunroof comprising a functional laminate, functional laminate of said type, and manufacture thereof

Abstract

The invention relates to a process for manufacturing an illuminable laminated sunroof from a triple-layer laminate.

Description

[0001] DESCRIPTION

[0002] TITLE: MANUFACTURE OF AN ILLUMINABLE LAMINATED VEHICLE GLASS ROOF WITH FUNCTIONAL LAMINATE, SUCH A FUNCTIONAL LAMINATE AND ITS MANUFACTURE

[0003] The present invention relates to the manufacture of an illuminated laminated glass roof for a vehicle with a functional laminate, a functional laminate and its manufacture.

[0004] There are panoramic laminated roofs with lighting by light-emitting diodes as described in document WO2010049638. The light emitted by the diodes is introduced through the edge into the interior glazing forming a guide, the light being extracted from the glazing by a diffusing layer on the glazing.

[0005] Document W02021005162 proposes a luminous laminated vehicle roof comprising in its example 2 in relation to figure 2 in this order:

[0006] - a first sheet of glass, forming the outer glass, tinted and coated with a low refractive index layer

[0007] - a first interlayer of lamination, polymer, low refractive index layer side

[0008] - a second interlayer of lamination, based on polyvinyl butyral (PVB) without plasticizer, of 30 pm which is functionalized by being coated with a light extraction layer which is a printed ink comprising TiCh particles in a polyurethane matrix, ink on the first interlayer side,

[0009] - a second sheet of extra-clear glass forming the inner glass.

[0010] The manufacture of such a roof involves:

[0011] - the deposition by flexography of the ink on the second interlayer which forms a temporary laminate with a temporary plastic film of 30pm, for holding during printing, the maintenance of the layers being electrostatic

[0012] - removal of the temporary plastic film

[0013] - the placement of this second interlayer on the second sheet of glass, printed layer facing upwards

[0014] - the placement of the first interlayer on the second interlayer.

[0015] The present invention sought to further improve the manufacture of such an illuminated laminated glass roof for a vehicle (speed, reliability, etc.).

[0016] To this end, the present invention firstly relates to a method for manufacturing a laminated (curved) glazed roof for a vehicle, in particular a road vehicle (automobile: car, truck, public transport: bus, coach, etc.) or a railway vehicle (trains, metros, trams), comprising: a curved laminated glazing unit - transparent (at least in one clear (central) window) - comprising:

[0017] - a first (curved), transparent sheet of mineral glass, possibly tinted in particular gray or green, intended to form the outer glass, with (a first edge and) a first main face F1 (intended to be oriented towards the outside of the vehicle) and a second main face F2 opposite, bare or coated with a transparent functional coating (in the clear of the window), first sheet in particular with a thickness of at most 1 m or 200 nm, for a road motor vehicle and even a car, first sheet with a thickness preferably of at most 4 mm, or even of at most 2.5 mm, even of at most 2.2 mm - in particular 1.9 mm, 1.8 mm, 1.6 mm and 1.4 mm - and even with a thickness of at least 0.7 mm, for example with a refractive index nv of at least 1.5 in the visible

[0018] - a polymer lamination interlayer, transparent (at least in the clear (central) glass)

[0019] - in adhesive contact with the third face F3, bare or coated, and with the second face F2, bare or coated, preferably thermoplastic, comprising a first interlayer, thermoplastic (clear or tinted, preferably in sheet form during manufacture), possibly forming an upper interlayer, i.e. in adhesive contact with the second face F2 or with a transparent functional coating (in particular with a thickness of at most 1 pm or 200 nm, in the clear glass) on the face F2, mono or multi-layer, in particular if acoustic PVB, or forming an intermediate interlayer, mono or even multi-layer), and a second interlayer, called the lower interlayer (clear), thermoplastic (mono or multi-layer, in particular if acoustic PVB)

[0020] - a light extraction layer, preferably in the form of a diffusing coating comprising a matrix (preferably organic) and diffusing particles, in contact with the lower interlayer

[0021] - a second (curved) sheet, transparent (at least in the clear (central) window), made of mineral or polymer glass, preferably extra-clear, with a refractive index n1 in the visible, with (a second edge and) a third main face F3 and a fourth main face F4 opposite, preferably bare or even coated with a functional coating (transparent) in the clear window, with a thickness of at most 1 pm or 200 nm, second sheet preferably made of mineral glass, third face F3 facing the outside of the vehicle and fourth face F4 towards the passenger compartment, in particular with a thickness of at least 0.7 mm (to promote light guidance), possibly with a thickness less than that of the first sheet of glass, even at most 2.2 mm - in particular 1.9 mm, 1.8 mm, 1.6 mm and 1.4 mm - or even at most 1.3 mm or at most 1 mm, the total thickness of the first and second sheets preferably being strictly less than 5 or 4mm, even 3.7mm.

[0022] The laminated glazed roof according to the invention further comprising between the face F2 and the face F3, an optical insulating layer, with a refractive index n2 in the visible, such that n2 <n1 , notamment couche isolateur optique, transparente (au moins dans le clair de vitre (central), - d’épaisseur E2 submillimétrique et d’au moins 400nm et même d’au moins 800nm ou 1 pm-, La couche intercalaire inférieure s’étend entre la première couche intercalaire et la face F3 (et même en contact adhésif avec la face F3 de préférence nue), et la couche d’extraction de lumière (revêtement diffusant de préférence) étant en contact avec la couche intercalaire inférieure et entre la couche isolateur optique et la face F3, notamment sur la couche intercalaire inférieure ou sur le revêtement isolateur optique.

[0023] The process involves in this order:

[0024] - an assembly step comprising:

[0025] - placement on one of the first and second sheets, called the reference sheet, of the first interlayer and the lower interlayer (direct placement, in contact with the reference sheet or on one or more additional layers (electroactive or electro-optical element, etc., as detailed later), in particular if the reference sheet is the first sheet),

[0026] - a positioning of the other of the first and second sheets, called the other sheet,

[0027] - a lamination (of a glazed assembly comprising between the first and second sheets, the lamination interlayer, the optical isolating layer, the light extraction layer, etc.). According to the invention, the assembly comprises the placement on the reference sheet of a functional laminate comprising a laminated (pre-laminated) three-layer comprising in this order:

[0028] - the first interlayer with a thickness E1 of at least 0.3 mm and better still at most 0.9 mm or 0.6 mm, in particular based on a first polymer (in particular based on PVB with at least 20% plasticizers)

[0029] - said optical isolator layer (set back and encapsulated by the first interlayer and the lower interlayer or with a free edge), said optical isolator layer comprising (even consisting of) or being supported by a first thermoplastic polymer film (non-adhesive, in particular polyester, in particular PET or polyolefin) with a thickness Ep of at least 20 pm, 30 pm or 40 pm and preferably at most 200 pm, or better still at most 125 pm or even at most 100 pm or 75 pm (chosen according to its rigidity to facilitate the manufacture of the three-layer)

[0030] - the lower interlayer of thickness Ei preferably at least 20pm or 25pm, preferably based on a second polymer identical or similar to the first polymer (in particular PVB (usual) plasticized with at least 15% or 20% of plasticizers or TPU or EVA (thermoplastic or crosslinked) preferably Ei of at least 0.3mm or based on PVB (low plasticization or without plasticizer) with at most 10% or 5% or 1% of plasticizers (and preferably Ei is at most 100pm or 80pm or 50pm), in particular a thickness E'= Ei+Ep is defined.

[0031] Furthermore, the laminate preferably carries the light extraction layer, in the form of a diffusing coating, in particular in the form of one or more diffusing patterns (in the clear view), in particular with a refractive index n4 in the visible, preferably n4 greater than or equal to n1 or less than n1 with n4-n1 of at most 0.1 or better still at most 0.05. Optionally, the roof has a haze of at most 30% or 20% or 10% in the area with diffusing pattern(s)). The invention simplifies and makes the manufacturing process of the illuminable roof more reliable in several respects. Firstly, the fact of producing the functional laminate upstream makes it possible to position only a single element on the reference sheet rather than proceeding sheet by sheet.

[0032] Then, unlike the temporary laminate of the prior art which requires the removal of the temporary film at the time of placement, the functional laminate according to the invention may have only functional layers, without a sacrificial temporary layer. The functional laminate may be ready to use and available in a roll, which can be unrolled.

[0033] Furthermore, the trilayer incorporates the optical isolator layer which allows if necessary to add a functional coating on the F2 face (solar control etc) and to have a more reliable optical isolator layer. In particular, control of the thickness of the optical isolator film or (preferably) of the optical isolator layer coated on the first, flexible, flat film is easier than a coating on the first curved glass sheet.

[0034] For optimal integration, the trilayer also incorporates the light extraction layer which can be not only on the F3 face side as in the prior art but within the trilayer, in particular deposited on the first film (in particular on the optical isolator layer which is preferably an optical isolator coating). In particular, it may be desirable not to weaken the F3 face by a coating.

[0035] Furthermore, with the three-layer rather than the sheet-by-sheet process, it is possible to laminate glasses of greater complexity without creases being generated by the lamination in the interlayers.

[0036] Furthermore, with the three-layer rather than the sheet-by-sheet process, degassing is already partly done during the three-layer formation phase.

[0037] The first polymer film is chosen to be thin in particular to limit the local volume gain effect. The first polymer film with an optical isolator coating or optical isolator itself can be available in roll or sheet form.

[0038] The first individual, thin polymer film would be:

[0039] - difficult to handle, with the risk of flying away because it is too light

[0040] - subject to tearing when robots transport it, or when cut

[0041] - creases, especially marking folds and bumps when cutting (when vacuuming on the cutting machine to the shape of the glazing etc.).

[0042] Unstacking it into a sheet or removing it from a roll would make it very electrostatic so that it would attract and trap dust, requiring working in a very clean environment or adding another electrostatic discharge step that would cancel out the electrostatic forces plating the dust onto the first film.

[0043] Conversely, since the first polymer film according to the invention is already protected by the interlayers of the laminated trilayer, the step of unstacking or extracting from a roll does not mechanically alter the first polymer film or degrade the optical insulation function or transparency. Handling problems may also arise with the lower interlayer alone (in sheet form) which may be as thin as 20 μm, in particular functionalized by carrying the light extraction layer.

[0044] In addition, the thicker first interlayer facilitates wrinkle-free cutting and wrinkle-free placement not only of the first film but also of a possibly thin lower interlayer.

[0045] Furthermore, all layers of the tri-layer (laminate) are precisely positioned at the same time on the reference sheet. In particular, in a sheet-fed process, if the first film were alone, it would have to be cut to the shape of the glazing, and positioned correctly, which adds process steps.

[0046] The use of the functional laminate according to the invention also reduces quality rejects by reducing the number and interfaces of the interlayers, thus reducing the probability of trapping dust or fibers and which would lead to eliminating products due to appearance defects, once the latter have reached complete transparency at the end of lamination (degassing, autoclave).

[0047] Furthermore, the quality of the laminate can be easily controlled earlier in the roof manufacturing process, without sacrificing glass sheets.

[0048] The proposed solution therefore consists of preparing the functional laminate with the laminated trilayer (and even laminate with one or more other laminated layers and / or bonded to another or other layers as described later) before placement on the reference sheet in order to reduce the number of process steps, the duration, particularly in the clean room, and to facilitate handling and quality control.

[0049] Once the laminated tri-layer (or even a laminated multi-layer greater than 3 layers) is ready, it can be:

[0050] - placed on the reference sheet, in particular the second glass sheet

[0051] - or placed (the first interlayer preferably) on another layer (sheet etc) in particular forming part of a stack (layers already pre-assembled or not), called upper block, in particular with one or more functional polymer films (thermoplastic, non-adhesive) and / or one or more electroactive elements (electro-optical); in particular based on liquid crystals with possibly a dichroic, electrochromic, photovoltaic etc dye), and at least one third interlayer lamination layer (intended to be placed on the first glass sheet), the three-layer assembly and upper block being able to be secured (locally) before being placed on the reference sheet, preferably the second glass sheet (face F3).

[0052] If necessary, before placement on the reference sheet, preferably the second glass sheet (F3 face), the laminated three-layer is cut (partially or completely) and / or bonded with an interlayer frame at its periphery (contoured to the shape of the glazing). Of course, the first film sandwiched between the interlayers provides sufficient adhesion with the interlayers to allow cutting and handling and maintain good adhesion after lamination.

[0053] The multi-layer laminate may consist of the laminated three-layer or even include another or other layers integral with the laminated three-layer (in particular by local bonds, local heating of interlayer material, etc.) or even laminated layers (in adhesive contact with each other and) with the three-layer, the multi-layer laminate is then a laminated multi-layer of at least 4 or 5, 6 layers or even 7, 8 or 9 layers (in adhesive contact with each other).

[0054] Preferably, the multi-layer laminate comprises at most 3 or 2 or 1 additional lamination interlayers (in particular from additional interlayer sheets), at most two or one functional film (transparent, preferably polymer) and / or an electroactive (or electrooptical) element, in particular based on liquid crystals or electrochromic or even photovoltaic. In particular, the laminate comprises a laminated multilayer including: third interlayer / functional film and / or electroactive element (chosen to be laminable) / trilayer. In particular, the laminate comprises a third interlayer and an electroactive element (in contact with the first interlayer), third interlayer secured to the first interlayer and / or an interlayer frame on the periphery of the first interlayer.

[0055] The (each) functional film and / or electroactive element is not necessarily the same size as the first film.

[0056] The thickness E1 of the laminate can be at most 8mm or even at most 6mm. The length L1 of the laminate can be at least 600mm and better at most 2000mm. The width W1 of the laminate can be at least 600mm and better at most 1500mm to be easy to handle and more compatible with roll-by-roll manufacturing. For example, care must be taken to ensure that a roll carrying the rolled laminate is not too heavy and / or long.

[0057] The general shape of the laminate may be custom-made, in particular regular or irregular, and in particular homothetic to the shape of the glazing. For example, the laminate is generally quadrilateral in shape, in particular rectangular, possibly with a rounded outline. The longitudinal edges of the laminate (and even of the first and second sheets of glass) may be straight or curved, in particular flared.

[0058] Preferably the laminate is free of additional glue (pressure-sensitive adhesive, etc.), the cohesion of the assembly, the adhesion between layers being achieved thanks to the adhesive interlayer lamination material.

[0059] E1 is at least 0.3mm to facilitate the manufacture of the three-layer (given the flexibility of the interlayer material), to provide good cohesion properties for the glazed roof (and protection in the event of breakage). Of course, it is possible that in the laminated laminate before placement on the reference sheet as after laminating the glazing:

[0060] - the possible interface between the first interlayer and the lower interlayer is indistinguishable (especially if based on the same material and the same color)

[0061] - the possible interface between an interlayer frame and first interlayer or lower interlayer is indistinguishable (especially if based on the same material and the same color)

[0062] - the possible interface between layers (sheets) of a multi-layer interlayer frame is indistinguishable (especially if based on the same material and the same color)

[0063] Preferably the laminated three-layer is preferably obtained from at least 2 sheets: the first film and the first interlayer, in sheet, and even from 3 sheets with the lower interlayer.

[0064] The reference sheet is preferably the second (inner, curved) sheet and presented with its convex surface facing upwards as this facilitates positioning of the laminate. Positioning the initially flat laminate on a concave surface forces the laminate to curl up, creating ripples while positioning it on a convex surface allows it to expand and deform more freely.

[0065] Alternatively, the reference sheet is the first (outer) sheet and shown with its concave surface facing upwards.

[0066] Before lamination, a glazed assembly can be formed comprising first sheet / (other sheet(s) / ) three-layer / second sheet or even first sheet / multi-layer laminate (three-layer or more, in particular laminated or integral as already described with one or more intermediate layers) / second sheet.

[0067] The lamination (of the glazed assembly, to form the laminated roof) is carried out at appropriate temperatures and pressures, (for example, in particular for PVB-based lamination interlayer (plasticized, unplasticized), by pressurizing preferably at least 5 bars and at most 14 bars and heating at least 100°C and at most 150°C, in particular by autoclaving.

[0068] Lamination may include placing the glass assembly in a vacuum at room temperature so as to evacuate the air (degassing operation) between the two sheets of glass (between trilaminat or other sheet(s) etc.), then heating the glass assembly to a suitable temperature while continuing to subject it to a vacuum.

[0069] In a step consisting of heating the glass assembly by subjecting it to a vacuum, an additional external pressure is not simultaneously applied to it, as for example in an autoclave.

[0070] When the glass unit is subjected to a vacuum, there is sealed confinement of the entire periphery of the glass unit and suction in the confined peripheral volume. The glass unit is, for example, subjected to a vacuum by means of a vacuum chamber or a vacuum bag.

[0071] For lamination, for example, a sealed elastomer envelope is fitted over the entire peripheral part of the glass assembly, equipped with an orifice through which a vacuum is created by suction. The sealed envelope is often referred to by the English term "vacuum ring". The air present between the two sheets of cold glass is therefore sucked out for a period of 15 to 45 minutes, then heated to a temperature of 80°C to 120°C for a period of 30 to 60 minutes.

[0072] An alternative to this final vacuum stage may consist of placing the glass assembly in a vacuum enclosure or a vacuum bag, at least part of the walls of which are rigid so as to protect any peripheral element of the glass assembly by preventing it from being subjected to physical contact under excessive mechanical stress.

[0073] As a peripheral element, we can cite an electrical connection element which is connected to an electroactive (electro-optical) element, in particular based on liquid crystals, possibly with a dichroic, or electrochromic or even photovoltaic dye, between the two sheets of glass. For example, such a connection element or other is between the two sheets and extends outside the glass assembly (for example along the edge of the glass assembly).

[0074] Preferably, after lamination, the first film does not extend to the edge of the sheets (first sheet, second sheet), in particular the first film has an edge which is protected by the interlayer material (frame and / or said first interlayer or lower interlayer), avoiding edge sealing problems, lack of adhesion for the total glazing, water infiltration and oxidation.

[0075] In the present invention, for each layer (film, sheet, in particular interlayer; first film, three-layer, etc.), between the first and second glass sheets, the rear main face is understood to mean the face which is or is intended to be oriented towards the face F3, and the front main face is understood to mean the face which is or is intended to be oriented towards the face F2.

[0076] Advantageously, in particular when in the three-layer the first polymer film has a free edge, the process comprises before lamination (of the glazed assembly):

[0077] - a bonding (which is preferably an adhesive contact) - preferably direct, without the addition of additional adhesive - of a thermoplastic interlayer lamination frame (material identical to or chemically compatible with the material of the first interlayer and lower interlayer, frame of thickness Ec), with the three-layer, bonding preferably by local (point) bonds with an interlayer edge of at least one of the first interlayer and lower interlayer and possibly the free edge (of the first film), in particular bonding by (local) softening of the interlayer lamination material (of the frame and / or of the three-layer), preferably by local heating.

[0078] (Local) softening is by application of a chemical solution such as alcohol or preferably by local heating (heat input giving cohesion throughout between frame / first film and between interlayer frame / interlayer).

[0079] Local connections are made, in particular spot welds, preferably after (or after) contact (or close to at most 5mm or 1mm if local heating) of the frame with the three-layer, possibly with a cut-out part of the three-layer (cut-out layer).

[0080] Preferably:

[0081] - at least 1, 2, 3, 4 local connections are made (distributed around the perimeter), in particular at least one per edge of the three-layer (for example lateral and longitudinal),

[0082] - local connections preferably at least 1mm or 5mm long and at most 30mm or 15mm and spaced at least 10 or 15cm apart and even at most 80 or 50cm apart.

[0083] During said lamination, the free edge of the first film is encapsulated by lamination interlayer material.

[0084] The lamination interlayer frame is preferably, for handling, monolithic (in one piece) or in several parts joined together or even spaced at most 1 mm apart, for example one or more parts (strips) carrying a light redirection element.

[0085] The lamination interlayer frame may be at least 20mm wide (for its integrity, handling and to ensure sealing) and preferably at most 100mm or 50mm, preferably with a thickness Ec of at least 0.3mm. It may be of sufficient width to secure a functional element such as a light redirection element described later.

[0086] Thus, the joining is preferably carried out by adhesive contact, not involving the addition of adhesive material, preferably by (local) softening of the interlayer material which leads to adhesive contact between surfaces.

[0087] Advantageously, the joining (adhesive contact) is by local heating and possibly also by pressure, in particular induction heating, by hot air, by radiation (laser).

[0088] As a local and even multi-local heating tool (and better pressure) you can use a metal pen, a "soldering iron", with a flat tip (and preferably with a non-stick film (silicone, polytetrafluoroethylene -PTFE- such as Teflon®, elastomer etc) capable of letting the heat pass through, one or more heating fingers (in non-stick material in particular silicone, polytetrafluoroethylene, elastomer etc), a hot air gun.

[0089] The temperature and pressure are adjusted according to the interlayer material (preferably PVB) and the tool. Typically with a soldering iron, the temperature is at least 200°C or 250°C and the welds are quick and deep, without pressure required; with heated fingers, the temperature is at least 100°C.

[0090] The contact zones for the local connections can be centered a few mm from the boundary (junction or space of at most 1 mm) here between frame and trilayer and on either side of the boundary. For example, a heating finger (10 mm) is centered alternately on the trilayer (5 mm from the boundary) and on the frame (5 mm from the boundary). To be more compatible with the rate of an industrial line, it is possible to plan to carry out the various local connections, here between frame / trilayer (or any other joining with several local connections described later), in a single operation.

[0091] Thus, the bonding (adhesive contact), here of the frame with the three-layer, can be done in one operation for all the local connections. We can choose a heating tool that allows the various point adhesive points to be made in a single operation, for example using heating fingers.

[0092] Local heating can be by applying a heating tool to the front face of the laminate (towards face F2) and / or the back face.

[0093] This bonding is preferred to gluing using a bead of glue or double-sided adhesive, possibly punctual.

[0094] Preferably, all the interlayer lamination material is based on the same polymer, in particular based on PVB, preferably plasticized (conventionally) for the interlayer frame and the first interlayer layer.

[0095] The intermediate frame can be:

[0096] - single layer (sheet) clear or tinted or even opaque

[0097] - multi-layer (multi-sheet) in particular with first and second sheets of distinct color, in particular the so-called upper sheet (oriented towards the F2 face). opaque (for light masking etc.).

[0098] Local heating can be used to form not only local adhesive contact between two elements but also to join together a stack of several layers or sheets.

[0099] The interlayer frame is not always necessary to protect the first film, in particular when in the three-layer Ep is at most 200pm and even at most 150pm or 100pm and the first polymer film is shorter (for example at least 3mm, or 5 or 10mm and at most 30mm (possibly depending on the extent of the peripheral masking frame, defining the clear view) than the first interlayer and the lower interlayer, -therefore already encapsulated by these interlayers then in adhesive contact with each other-.. However, it is still possible to provide such a frame and the securing of the frame (already described) for example which to center the laminate in the clear window by reducing its extent. Advantageously, the method comprises the placement on the reference sheet of the three-layer with said interlayer frame secured (linked by local bonds).

[0100] For example, the process includes:

[0101] - placement of the three-layer (previously cut) inside the interlayer frame (previously cut in an interlayer) - on a mounting table, preferably three-layer in frame rather than placing the frame on the edge of the three-layer) -

[0102] - joining the laminate and the intermediate frame so that the edges of the frame and the laminate are locally joined

[0103] - placement of the laminate assembly linked to the interlayer frame on the reference sheet (with centering in relation to it),

[0104] - or placement of the laminate assembly linked to the interlayer frame on a layer, in particular a stack of layers, securing by local connections, placement of the assembly on the reference sheet with centering relative to it.

[0105] During lamination, care must be taken to ensure that any interlayer material extends sufficiently and flows correctly to avoid breakage and bubbling. In particular, any functional element (first film, other functional polymer film, electroactive element, etc.) with a thickness of at least 200 μm inserted between two interlayers and shorter is preferably surrounded by an interlayer frame between the two interlayers.

[0106] In particular, in the assembly process (with autoclaving), the interlayer material (PVB etc.) has difficulty flowing over distances greater than a few millimeters. Any local excess thickness of the glazing (by an element) would cause deformation of the first and second sheets of glass. As a result, various undesirable phenomena can occur:

[0107] - breakage of one of the two glasses, due to excessive deformation of the latter, inducing excessive local extension constraints;

[0108] - bubbling introduced into the glazing, due to imperfect creep of the interlayer material during the lamination of the glazing; in particular this lack of interlayer material or a low partial pressure in the material promotes the formation of bubbles (by degassing of the small molecules present in the PVB etc.).

[0109] If necessary, the method may comprise a partial peripheral (circumferential) cutting of the trilayer (of the laminate), which is a total cutting over a thickness E' of the first film and of one of the first interlayer and lower interlayer, called the cut layer, leaving a frame surface preferably projecting with a width W1 of at least 20 mm (and preferably at most 200 mm) from the other of the first interlayer and lower interlayer, called the whole layer.

[0110] To limit the risks of breakage or bubbling, the method further comprises, when E' > 200pm and even E' >150pm or even E' >100pm, the placement of an interlayer frame (to be more easily handled without folds etc., preferably with a width Wc of at least 20mm, in particular Wc less than or equal to the width W1, and / or a thickness Ec of at least 0.3mm) on the protruding frame surface. In particular, during lamination, the first film is encapsulated by lamination interlayer material.

[0111] The interlayer frame is in contact with the cut layer or spaced at most 5mm or 1mm apart and is edge to edge with the entire layer or offset at most 5mm or 1mm).

[0112] This intermediate frame can be used:

[0113] - to protect the free song of the first film as mentioned above

[0114] - and / or to arrange at least one functional element (light redirection element(s) etc.) near the three-layer

[0115] - and / or being tinted and even opaque (to eliminate stray light etc.).

[0116] To also limit the risks of breakage or bubbling, when the entire layer is the first interlayer, the interlayer frame is preferably positioned to be flush with the free face known as the rear face of the lower interlayer (oriented towards face F3 after placement on the reference sheet), or being offset by at most 100 pm (under flush or over flush).

[0117] During lamination, the first film is encapsulated (coated) by interlayer material (by creep of the interlayer frame and / or the entire layer).

[0118] In particular when the back (free) face of the lower interlayer does not carry the light extraction layer, the lower interlayer in particular based on PVB with at least 10% or 15% or even 20% of plasticizers, it may be desirable that the back (free) face of the lower interlayer has a minimal roughness, promoting degassing, satisfactory lamination. In particular the roughness parameter Rz, is at least 10pm or even 50pm.

[0119] In particular, the first interlayer is based on PVB with at least 20% plasticizers, it is also desirable that the front (free) face of the first interlayer (oriented towards the F2 face after placement on the reference sheet) has minimal roughness, promoting degassing and satisfactory lamination. In particular, the roughness parameter Rz is at least 10 pm or even 50 pm.

[0120] When E'< 200pm and better at most 150pm or 10Opm and the entire layer is the first interlayer with a thickness of at least 0.3mm, during lamination the entire layer flows and encapsulates (coats) the first film.

[0121] It is also possible to cut the entire laminate (of the entire laminated part of the three-layer laminate or more) (preferably before any local bonding) to a predetermined shape. In particular, it is possible to cut the entire three-layer (preferably before any local bonding of the three-layer with another element such as the intermediate frame, etc.) to a predetermined shape. Preferably, an automatic cutting system is used, itself composed of a table, possibly a belt, a blade supported in an orientable tool which is itself integral with a horizontal movement system (in XY) of the carriage type mounted on a bridge and making it possible to cut:

[0122] - an interlayer of lamination to form the interlayer frame

[0123] - and / or the laminate (three layers or more).

[0124] By combining the different movements, it is possible to make the blade follow any cutting paths. For example, a blade moves in the X axis of a bar and the bar moves in Y in the axis of the belt

[0125] Preferably, to press the element to be cut, there is suction by means of holes in the belt.

[0126] Several configurations can be provided to correctly position the edges of the interlayers (including any frame).

[0127] In particular in a first configuration:

[0128] - the edge of the lamination interlayer has an overhang of between 5 and 20 mm compared to the edges of the glass sheets,

[0129] - the process includes trimming the interlayer material before degassing (i.e. cutting the interlayer material to be edge to edge with the glass sheets)

[0130] - after autoclave, the process includes brushing (removing) excess interlayer material from the edge of the glass sheets.

[0131] In particular in a second configuration, the edge of the lamination interlayer has a withdrawal of 0 to 4 mm compared to the edges of the glass sheets.

[0132] We prefer the second configuration because:

[0133] - having the edge of the interlayer slightly set back from the glass edge limits light leaks through the glass edge,

[0134] - the first and second slices (of the glass sheets) are preferably encapsulated subsequently, by an opaque polymeric encapsulation (black etc.), so the glass edges are not visible, for example PU encapsulation, for example as described in application WO2010 / 049638

[0135] - not having to deburr or brush avoids operations and therefore losses in yield,

[0136] - deburring and brushing a thick multi-layer of interlayer is more complex.

[0137] The method may further comprise:

[0138] - the provision of at least one light redirection element, in particular on the periphery of the window clear, in particular two light redirection elements (in particular on the periphery of the window clear on two opposite edges), light redirection element (prismatic) which is transparent (prism etc) on the F4 face side or preferably (F3 face side) which is a reflective prismatic film comprising a main textured face with reflective prisms and an opposite main face, called the smooth (non-textured) face.

[0139] And preferably it includes:

[0140] - another bonding (which is preferably an adhesive contact) preferably direct, without the addition of additional adhesive, of said light redirection element (light redirected towards the face F3) with an interlayer material of the trilayer (first and / or lower interlayer), in particular by local bond(s), other bonding forming local bond(s) by local softening of the interlayer material of the trilayer, preferably by local heating,

[0141] - and / or a pre-bonding (which is preferably an adhesive contact) of said light redirection element (light redirected towards the face F3) with an interlayer material of an interlayer lamination frame (frame already secured to the three-layer or subsequently secured to the three-layer, in particular the bonding already described), in particular the pre-bonding forming local bond(s) by local softening of the interlayer lamination frame, preferably by local heating

[0142] - or the placement of the chosen light redirection element prismatic reflector film on face F3, reflector prisms oriented towards face F2

[0143] - or the placement of the chosen light redirection element prismatic reflector film on the F3 face, with gluing on the F3 face via local glue of the reflector prisms oriented towards the F3 face.

[0144] In particular (as for the frame / three-layer bonding already described), the local connection(s) are at least 1mm or 5mm long and at most 10mm long and spaced at least 10, 15cm apart and at most 80, 50cm apart.

[0145] It may be desirable to limit the number of local connections so as not to alter the optical function of this light redirection element (transparency, etc.). For example, at most 1, 2 or 3 local connections are made.

[0146] (Local) softening can be by application of a chemical solution such as alcohol or preferably by local heating (generating adhesion, adhesive contact light redirection element / interlayer material). Local connections, in particular spot welds, are made preferably following (or delayed) the contact (or at most 5 mm or 1 mm in the case of local heating) of the light redirection element with the interlayer material.

[0147] Preferably, the other joining and / or the pre-joining is before being placed on the reference sheet or even before being placed on an additional functional element (functional polymer film, electroactive element, in particular based on liquid crystals or electrochromic or even photovoltaic), in particular the front face of the first interlayer in contact with the rear face of the additional functional element.

[0148] The light redirection element which is a reflective prismatic film is preferably of thickness Er < 200pm and even at most 150pm, to avoid the addition of an interlayer frame, and preferably is a reflective prismatic film.

[0149] In particular during said lamination (of the glass assembly) the light redirection element is encapsulated by interlayer material.

[0150] The light redirection element (transparent on the F4 face side or reflector on the F3 face side) is capable of receiving light (by row(s) of diodes etc. normal to the glazing or inclined) on the F4 face side, passing through the second sheet, and returning it to the second sheet for propagation by total reflection. The light redirection element, in particular the reflector, is elongated to receive light, for example, from a row of diodes (preferably a straight strip of at least 5 cm, in one or more sections, connected or not).

[0151] Preferably, the light redirecting element is a reflective prismatic film at least 1 cm wide and at most 5 cm long, having a flat face and a face with reflective prisms (monolithic film or with a textured coating, such as an embossed resin).

[0152] In order to avoid folds and undulations, the first film and / or the prismatic film (reflector) may be in an area of ​​the roof with a curvature or sphericity limited in particular by a radius of curvature of at least 1.5 m.

[0153] The light redirection element (the reflective prismatic film) is preferably of thickness Er less than 200pm and even at most 150pm or 100pm to avoid the addition of a dedicated interlayer frame surrounding it.

[0154] The substrate film or base of the (micro)prisms can be less than 200 pm, 100 pm, 80 pm or 50 pm and even at least 30 pm. For example, it is a film (thermoplastic, polyester, PET) which can be tinted and even opaque if the prisms are oriented towards the third face F3. The prisms can be at least 1 pm high and preferably at most 100 or 50 pm or 30 pm.

[0155] Preferably, the prismatic (reflective) part of the reflective prismatic film is on, or even in contact with, a local adhesive or the interlayer material (of the first interlayer, of the lower interlayer, of the frame) to protect the vertices, and even sinks into the interlayer material during lamination (in the case of slight excess thickness). A thickness of this interlayer material of at least 25 μm and better 50 μm or 100 μm is preferred).

[0156] The light redirecting element, in particular the (first) prismatic reflective film, may be under the first film or adjacent to the first film, possibly slightly offset in height from the first film. The (first) prismatic reflective film may extend along the first longitudinal edge, preferably at a constant distance from the window clear (inner edge of the peripheral masking frame) or from a first lateral edge (at the front or rear of the roof). Several prismatic reflective films may be abutted or separated along a first edge.

[0157] It is possible to add (at least) another (second) prismatic reflective film on a second edge, in particular an edge opposite the first edge, in particular a film similar or identical to the first prismatic reflective film, opposite the first prismatic reflective film.

[0158] In a first configuration, the light redirection element is a reflective prismatic film, comprising a textured main face with reflective prisms and an opposite main face called the smooth face, preferably with a thickness Er <200 pm or at most 150 pm and better still at least 70 pm, with the textured face oriented towards the first interlayer (smooth face oriented towards the lower interlayer, towards the face F3), the reflective prismatic film is positioned to be opposite, adjacent or offset (distant) by at most 4 mm or 1 mm with the first film (with its external edge), and the optional optical insulating coating is preferably up to the edge of the first film or set back by at most 1 mm from the edge of the first film a) before the other joining with the trilayer, a contacting (a laying) of said reflective prismatic film (of the smooth face, here rear face) on a rear main face of the lower interlayer,intended to be oriented towards the face F3, the reflective prismatic film is preferably positioned to be at least partly opposite the first film and in particular before lamination the so-called smooth face of the prismatic film opposite the prisms is on the face F3 (preferably in contact with) b) or, before or simultaneously with the joining with the three-layer, the pre-joining of the reflective prismatic film (of the smooth face, here the rear face):,

[0159] - with a main face (front or back) of a lamination interlayer frame

[0160] - or within an interlayer lamination frame, in particular multi-layer (multi-leaf), preferably based on plasticized PVB (with at least 20% plasticizer).

[0161] The reflective prismatic film can be under the first film or adjacent to the first film, possibly slightly offset in height (towards face F2) with the first film.

[0162] When the reflective prismatic film is positioned to be adjacent to the first film, attached or at most 4 mm or 1 mm apart, preferably, the base or the top of the reflective prisms (oriented towards the first interlayer) of the reflective prismatic film is preferably above at most 30 pm (from the front face of) the optical isolator layer, in particular (from the front face of the first film). In one configuration, the reflective prismatic film can be positioned straddling the rear free face of the three-layer and the rear face of the interlayer frame (in particular already secured to the three-layer).

[0163] Before lamination, the so-called smooth face opposite the prisms can preferably be placed directly on face F3, in particular the main front face intended to be oriented towards face F2.

[0164] Before lamination, the so-called smooth face opposite the prisms may be on the front face of the frame and, preferably, the textured face (the reflector prisms) being further bonded to an interlayer material of another lamination interlayer frame or of a third lamination interlayer or of the first interlayer.

[0165] In a second preferred configuration, the light redirection element is a reflective prismatic film comprising a main face textured with reflective prisms and an opposite main face called the smooth face, preferably having a thickness Er of less than 200 pm or at most 150 pm and even at least 70 pm and, the method comprises the placement of the reflective prisms:

[0166] - on a surface (frame) protruding from the three-layer, after partial (circumferential) cutting of the three-layer,

[0167] - on the main face of an intermediate frame (attached to the three-layer or subsequently attached as already explained), in particular the main front face intended to be oriented towards face F2

[0168] - or within an intermediate frame, in particular a multi-layer (multi-sheet), preferably based on plasticized PVB (with at least 20% plasticizer) - (bonded, integral with the three-layer or bonded, subsequently secured -

[0169] - on the F3 face by means of the local glue (transparent) binding the F3 face and the reflector prisms and the reflector prisms being oriented towards the F3 face.

[0170] The thickness of the interlayer material (or local glue) receiving the reflecting prisms is preferably at least 25 pm and better still at least 30 pm, 50 pm or 80 pm (in particular PVB with less than 5% plasticizers and even without) and preferably at most 400 pm (in particular PVB with at least 20 or 30% plasticizers and even without, at least 350 pm).

[0171] Preferably, the smooth face is further bonded to an interlayer material of another lamination interlayer frame or a third lamination interlayer (of said lamination interlayer) or to the lower interlayer (if reflector prisms are bonded to the F3 face via local glue).

[0172] The reflective prismatic film (for example glued to the F3 face) can be under the first film or adjacent to the first film, possibly slightly offset in height from the first film.

[0173] When the reflective prismatic film is positioned to be adjacent to the first film, attached to or at most 4mm or 1mm apart from the first film, then preferably the bases or the tops of the reflective prisms (oriented towards the lower interlayer, towards the F3 face) are preferably above at most 30pm (from the front face) of the first film or even the optical isolating coating (in redirection of the F2 face).

[0174] Before lamination, the textured face (the reflector prisms) is preferably oriented towards the F3 face (reflector prisms in contact with the lower interlayer or with local glue). Alternatively, the light source is opposite the edge of the second sheet or is on the F4 side and coupled with a light redirection element in transmission on the F4 side (prism, prismatic film, etc.).

[0175] The prismatic film (reflector on the F3 side, or in transmission and on the F4 side) and the first film can be partially or completely superimposed.

[0176] Before lamination, the first interlayer, forming the upper interlayer, comes into contact with the bare F2 face or with a transparent electrically conductive functional coating on the F2 face.

[0177] Before lamination, alternatively, the first interlayer, forming an intermediate interlayer, comes into contact with an additional functional element, in particular an electroactive (electro-optical) element, in particular based on liquid crystals (before or without dichroic dye) or electrochromic or even photovoltaic (with solar cells) surmounted by a third interlayer of the lamination interlayer, coming into contact with the bare face F2 or with a transparent electroconductive functional coating on the face F2.

[0178] An upper block can thus include the third interlayer / additional functional element assembly (and even another interlayer frame around the perimeter of the additional functional element).

[0179] A lower block may comprise the laminate and possibly an interlayer frame secured to the three-layer, in contact or better secured (locally) to the upper block (by softening of interlayer material, for example interlayer frame and / or other interlayer frame).

[0180] Also in one embodiment, preferably before placement on the reference sheet preferably which is the second glass sheet,:

[0181] - the provision of an additional stack, called upper block, comprising an additional functional element and a third thermoplastic interlayer of lamination (of said interlayer of lamination), preferably plasticized PVB (with at least 20% plasticizer) the additional functional element which is: a) an electroactive (electro-optical) element, in particular based on liquid crystals or electrochromic or even photovoltaic (with solar cells), with another interlayer of lamination frame on the periphery of said electroactive element, in particular another interlayer of lamination frame preferably in local adhesive contact with the third interlayer of lamination, by local bonds, in particular local bonds by local softening of interlayer material, preferably by local heating b) another functional polymer film bonded (laminated) or in contact with the third interlayer of lamination, (mono or multifilms,in particular solar control, in particular with polymer film with solar control coating for example), and preferably:,

[0182] - on said additional functional element or even on the other intermediate frame, the placement of the laminated laminate with intermediate frame secured to the three-layer and / or light redirection element(s) secured to the three-layer, thus forming a lower block

[0183] - additional joining of the lower block with the upper block, preferably additional joining forming local bonds by local softening of the interlayer material, preferably by local heating.

[0184] In one embodiment, the method may comprise:

[0185] - the provision of a third thermoplastic interlayer (said lamination interlayer), preferably in sheet form and even with a thickness of at least 0.3 mm

[0186] - placement on the third interlayer preferably in this order:

[0187] - an intermediate lamination frame

[0188] - an additional functional element, which is an electroactive element, in particular based on liquid crystals or electrochromic or even photovoltaic, or another functional polymer film,

[0189] - of the three-layer (or of the laminated laminate, in particular consisting of the three-layer) on the additional functional element, placement so that the interlayer lamination frame is both on the periphery of the additional functional element and of the three-layer (of the laminated laminate),

[0190] - a joining (preferably by adhesive contact) of said intermediate frame with the laminated laminate and the third intermediate layer, preferably joining forming local bonds by local softening of the intermediate material, by local heating (as already described). In one embodiment, the method may comprise: on the reference sheet which is the second sheet, the placement:

[0191] - at least one light redirection element, in particular a reflective prismatic film with a textured main face and an opposite main face called smooth on the third face, and an intermediate lamination frame

[0192] - preferably a joining (preferably in adhesive contact) of the intermediate frame with the third face by local connections, in particular local connections by local softening of the intermediate material, preferably by local heating

[0193] - the placement of the three-layer (of the functional laminate) with the lower interlayer on the third face so that the interlayer frame is on the periphery of the three-layer (of the functional laminate) - preferably a joining (adhesive contact) of the three-layer (of the functional laminate - in particular of the lower interlayer - with the third face and even said interlayer frame by local bonds, in particular by local softening of interlayer material, preferably by local heating

[0194] - placement of the first sheet on the functional laminate and the interlayer frame.

[0195] This allows you to prepare in parallel (or in sequence on the same editing table)

[0196] - additional stacking, the upper block (cutting, local connections with other intermediate lamination frame, etc.)

[0197] - and the laminate with interlayer lamination frame and / or redirection element(s).

[0198] It is preferable to bring the laminate (lower block) and the additional stack (upper block) into contact, to join them (locally) before placing them on the reference sheet.

[0199] In particular, it is preferred to place the laminate (lower block) on the additional stack (upper block), secure them (locally), turn the assembly over - manually or by robot(s) - and place it on the second sheet (face F3) which is the reference sheet.

[0200] Indeed, in the case of an additional stack which includes an electroactive element with an interlayer frame secured by local bonds to the third interlayer, it is preferable to place the laminate on the additional stack rather than the reverse when the electroactive element is not (always) secured to the third sheet (in its central part) and cannot be returned to the assembly table easily.

[0201] The cutting (of the frame and the trilaminate) is preferably carried out outside the laminate lamination line (by roll process, preferably roll to roll), in a clean atmosphere, as are the local connections.

[0202] In order for the different elements to remain firmly attached and positioned in relation to each other during the rest of the process, it is also possible to provide for a bonding by local connections, (local) softening of the interlayer material:

[0203] - after placing on the reference sheet (in particular if the second sheet) joining with the reference sheet of the laminate alone or of a complete block (comprising the upper block and the lower block)

[0204] - and / or after placing the other sheet of glass, joining (if necessary) with the other sheet of the laminate alone or of the complete block (comprising the upper block and the lower block).

[0205] When the reference sheet is the second sheet, the lower interlayer comes into contact with the bare F3 face preferably or with a functional coating (electroconductive, transparent etc.) on the F3 face.

[0206] The edge of the laminate is under a peripheral masking frame, for example in black enamel on face F2 and / or black ink on the first upper interlayer.

[0207] The edge of the laminate and even the complete block is under a peripheral masking frame, for example black enamel on face F2 and / or black ink on the third interlayer. The light extraction layer is preferably a diffusing coating which is:

[0208] - between the optical insulator layer and the lower interlayer (in particular PVB-based, notably with less than 20% plasticizers) with a coverage rate preferably of at most 30% (for cohesion).

[0209] - on the back face of the lower interlayer (F3 side), in particular based on PVB, notably with less than 20% plasticizers, with a coverage rate preferably of at most 30% or even at most 25% or 10% (for cohesion).

[0210] Each interlayer of lamination made of thermoplastic polymer material can be chosen from polyvinyl butyral (PVB), or even polyvinylacetate (PVA), ethylene-vinyl acetate (EVA), thermoplastic polyurethane (TPU) alone or in mixtures of several varieties of one of them and / or several of them; the term "varieties" here refers to variations in the plasticizer content, branching / linearity, average molecular mass of the molecules, etc.

[0211] Of course, we can prefer that each interlayer of the laminate be based on the same thermoplastic polymer (plasticized or not, tinted or not, etc.).

[0212] In particular, the lower interlayer (which is in contact with the diffusing coating) is based on PVB, in particular with less than 30% or 20% plasticizers, and the first layer (and even the upper interlayer) is based on PVB with plasticizers (usual PVB).

[0213] If necessary one of the interlayers of lamination can be an acoustic PVB, in particular:

[0214] - the outermost interlayer, i.e. in contact with the bare F2 face or with a coating on the F2 face: the first interlayer or the third interlayer or

[0215] - or the lower interlayer (in contact with the F3 face).

[0216] Also in this configuration the acoustic interlayer is multi-layered. The three-layer can therefore include a multi-layer for one of its interlayers.

[0217] The bottom interlayer is clear, the first interlayer can be clear or tinted.

[0218] For a clear interlayer, a light transmission of at least 90% is preferred.

[0219] The interlayer frame can be tinted (all or part) and even opaque.

[0220] The electroactive element (or any other additional film) is not necessarily of the same dimension as the three-layer (may be wider or shorter over all or part of its edge). In any case, it is preferred that the edges of the three-layer and of the electroactive element, of the third interlayer sheet (and even the interlayer frame(s) and any light redirection element, in particular a reflective prismatic film) are masked from the outside by a peripheral masking frame and even from the inside, for example, by a trim. Examples of electro-optical elements are SPD elements (SPD = Suspended Particle Device), known for example EP0876608B1 and WO2011033313A1, and PDLC elements (PDLC = Polymer Dispersed Liquid Crystal), known for example from DE102008026339A1. There are also electrochromic elements, known, for example, from EP3702572A1 or EP2917159A1.

[0221] Typically, the two electrodes are arranged between two carrier films, usually made of PET. Commercially available multi-layer films are also coated on both sides with a protective film made of polypropylene or polyethylene, which serves to protect the carrier films from dirt or scratches.

[0222] In a particularly preferred embodiment, the liquid crystal element is a PDLC (polymer dispersed liquid crystal) element. The PDLC element contains liquid crystals (in microdroplets) that are embedded in a polymer matrix and optionally a dichroic dye. If no voltage is applied to the PDLC element, the liquid crystals are aligned in disorder, which leads to strong scattering of light passing through the active layer (translucency). If a voltage is applied to the PDLC element, the liquid crystals align in a common direction and the transmission of light through the functional element is increased (transparency). However, it is also possible that the liquid crystals are ordered in an unstressed state and that the liquid crystals are accordingly disordered when a voltage is applied.However, other functional elements can also be used whose variability of optical properties is based on liquid crystals, such as PNLC (polymer networked liquid crystal) elements. If, in relation to the PDLC element, one speaks of the application of a voltage, then an alternating voltage (the effective value of the alternating voltage and not the instantaneous voltage) is intended for the purposes of the invention.

[0223] For example, the haze in the diffusing state of the roof with a PDLC layer is at least 80% and better 85%, 90%, 95%. With the addition of dichroic dye the tint can be variable.

[0224] In another preferred embodiment, the liquid crystal element is a guest host (GH) cell. The GH cell is color-variable (light to dark and vice versa), containing an electroactive layer comprising a liquid volume of liquid crystals mixed with dichroic (dissolved) dyes.

[0225] In another preferred embodiment, the element is an SPD (suspended particle device) element. The SPD element contains suspended particles. The suspended particles change the optical state of the functional element by absorbing light by applying a voltage. SPD functional elements therefore have switching states with transparent and opaque optical properties as well as intermediate steps between transparency and opacity. If, in relation to the functional element as an SPD element, one speaks of the application of a voltage, then an alternating voltage (the effective value of the alternating voltage and not the instantaneous voltage) is intended for the purposes of the invention.

[0226] In another preferred embodiment, the element is an electrochromic element. In this case, the transmission of visible light through the functional element depends on the degree of placement of the ions. The ions are released, for example, by an ion storage layer and stored in an electrochromic layer. The transmission can be influenced by the voltage applied to the functional element, which causes migration of the ions. Suitable electrochromic layers preferably contain at least tungsten oxide or vanadium oxide. If the functional element is an electrochromic functional element, the control unit is preferably not equipped with an inverter and a direct voltage is applied to the functional element. A DC / DC converter to achieve voltages between 1 V and 50 V and preferably from 10 V to 42 V, but may be part of the control unit as required.

[0227] The edge of the functional element (PDLC, GH, EC, solar, functional film) can be distant from the edge of the first sheet (or the third sheet) by at least 10mm and even by at least one of the following values: 15mm, 20mm, 25mm, 30mm.

[0228] The edge of the functional element and that of the coated substrate can be aligned or separated by at most 10cm or 5cm or 1cm.

[0229] The glazing may therefore include between the second face (F2) and the third face (F3), an opaque, internal peripheral masking layer, in particular an enamel (black etc.) on the second face or a coating on the lamination interlayer (upper interlayer or first interlayer) for example an opaque coating (PVB-based and with a coloring agent) on a main face of a PVB on the second or third face.

[0230] The internal masking layer can be 2mm or 3mm (less than 5mm) from the edge of the glazing or even up to the edge. The masking layer can be a strip framing the glazing (windshield, roof, etc.), particularly black. The entire periphery is opaque to hide bodywork elements or joints or to protect an adhesive for mounting on the vehicle. This internal masking layer in particular is in contact with the second main face. This internal masking layer delimits in particular the glass clear. It may be advantageous for the external edge of the optical insulating coating or more broadly any adhesive layer of the lamination interlayer to be masked by the internal masking layer, not to be in the glass clear. It may be advantageous for the external and even internal edges of the frame layer or to be masked by the internal masking layer, not to be in the glass clear, for the frame layer to be under the internal masking layer.

[0231] The width of the internal masking layer along the sides of a motor vehicle roof is generally less than that at the front or even at the rear. In particular, another masking layer, called the internal layer, may be on the fourth face, called F4, on the passenger compartment side, in particular facing the internal masking layer (and even of an identical nature, for example, an enamel, in particular black, on a second sheet of mineral glass). It may be adjacent to a possible transparent functional coating, in particular athermal, at least in the clear window.

[0232] In particular for an automobile roof (first sheet is the exterior glazing):

[0233] - the width of the internal (and even interior) masking layer along the longitudinal edges may be at most 30cm, in particular 10-20cm. the width of the internal (and even interior) masking layer along the rear lateral edge may be at most 40cm or 30cm, in particular at least 1cm or 5cm, and along the front lateral edge at most 60cm or 40cm, in particular at least 1cm or 5cm.

[0234] Preferably, concerning the light extraction layer preferably in the form of a diffusing coating, the diffusing particles (dielectric, organic or mineral for example metal oxides) have a particle size defined by D90 of less than 2 pm, preferably at least 100 nm and even at most 700 nm, in particular 400 nm ±100 nm.

[0235] Preferably, the diffusing particles are chosen from non-luminescent particles of TiCh, SiC>2, CaCCh, ZnO, AI2O3, ZrC>2. Preferably, the particles have a (high) refractive index, greater than or equal to 1.8 or even 2 (greater than n5, in particular at most 1.8 or 1.7).

[0236] The invention also relates to a laminated functional laminate (usable in the method described above) with a thickness of at most 8 mm or even at most 6 mm comprising a multi-layer assembly which according to the invention includes a laminated tri-layer comprising in this order:

[0237] - a first interlayer of lamination, thermoplastic, with a thickness E1 preferably of at least 0.3 mm (single or multi-layer in particular if acoustic PVB) and preferably of at most 1.2 mm

[0238] - an optical isolator layer which comprises or is supported by a first thermoplastic polymer film (preferably polyester, and even PET) with a thickness Ep of at least 20 or 50 pm and at most 200 pm or 125 pm or 100 pm

[0239] - a second interlayer of lamination called lower interlayer, thermoplastic, with a thickness Ei of at least 20 pm, (mono or multilayer, in particular sheet in particular if acoustic PVB) and preferably of at most 1.2 mm, the laminate carrying a light extraction layer which comprises and even in the form of a diffusing coating (on lower interlayer, on the front face (optical isolator layer side) or opposite rear face or on optical isolator layer which is preferably an optical isolator coating). In a first configuration which is preferred, the optical isolator layer comprises an optical isolator coating, preferably on a main face, preferably a rear face of the first film. The first film is a polyester film, in particular PET, or polyolefin (including polycarbonate) of 50 pm to 100 pm.

[0240] The first film, preferably PET, presents in particular:

[0241] - adhesion with the first interlayer and / or with the lower interlayer of at least 2N / m and even at least 3N / m,

[0242] - a roughness parameter Rz of at most 50pm (in particular for the main face, preferably the rear face, coated with an optical isolating coating).

[0243] A light transmission of the first film (and the lower interlayer) of at least 90% is preferred, a haze of at most 0.5% (measured in transmission according to ASTM D 1003). The optical isolating coating can be an organic matrix (crosslinked material etc.) or mineral (silica etc.) with porosities or hollow nanoparticles (of silica etc.) or (sufficiently) low index by its matrix itself.

[0244] Preferably the optical isolating coating is:

[0245] - a hard layer (hard coat), thanks to its matrix, - in particular which is not likely to be damaged by lamination by calendering the laminate.

[0246] Thus the optical isolator coating has a hardness of at least 1 H.

[0247] If necessary, the optical isolating coating is covered by a (harder) protective coating, e.g., organic, transparent, e.g., a dense layer made of the same matrix as the optical isolating coating, preferably at least 1 μm thick. And the light extraction layer in the form of a diffusing coating can be on the protective coating (and on the underlying optical isolating coating).

[0248] Advantageously, to further increase the luminance:

[0249] - the difference in refractive indices n1-n2 is at least 0.08 in the visible and better at least one of the following values: 0.09, 0.1, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, 0.3, 0.31, 0.32, 0.33, 0.34, 0.35,

[0250] - the thickness of the optical isolating coating is at least 800nm, 900nm, 1 pm and preferably less than or equal to one of the following values: 10pm, 5pm, 3pm, 2pm.

[0251] For mechanical strength (in particular if low index nanoparticles or porosities in the optical insulating coating) and / or depending on product availability (less easy at very low index), one may want to limit the difference in refractive indices n1-n2 and choose at most 0.2 or at most 0.15 and preferably at least 0.1, 0.11, 0.12 (in particular for n1 from 1.5 to 1.53).

[0252] The optical isolating coating may comprise at least 99% by weight of crosslinked polymer, optional photoinitiators, rheological agents.

[0253] The optical isolating coating is preferably deposited by liquid application. The surface of the optical isolating coating (before assembly) is non-sticky and involves the use of the lamination interlayer. In particular, the surface is then non-sticky to glass, to the touch.

[0254] The optical isolating coating is in particular a varnish which can be obtained from a photo-crosslinkable resin and with photoinitiators if necessary or even thermo-crosslinkable, a two-component mixture etc. A layer of crosslinkable resin is deposited on the first polymer film. Once the material is crosslinked, the free surface is not sticky.

[0255] In particular, the optical isolating coating comprises (is made up of) a crosslinked polymer matrix with said index n2 preferably of at most 1.42 (or 1.4 or 1.35), matrix preferably among polymers based on polyacrylate (for example to have a refractive index of at most 1.42 or 1.4) with possible fluorinated function (to have the lowest possible refractive index), in particular urethane acrylate or fluoro urethane acrylate or fluoro-silicone acrylate,

[0256] - or even silicone (for example with a refractive index of at most 1.4 or 1.3) in particular polydimethylsiloxane, epoxy polymer, polyepoxides, polyurethane, polyvinyl acetate, polyester.

[0257] Preferably the optical isolating coating is free of free silicone, volatile silicone component (source of surface pollution).

[0258] The crosslinked polymer material (of the optical isolating coating) may preferably be based on (or essentially consisting of) a polymer associated with one or more other functions such as the acrylate function for photo-crosslinking (crosslinked polymer material based on urethane acrylate or based on silicone acrylate) and / or the fluorinated function to lower the refractive index (crosslinked polymer material based on fluoro-urethane acrylate or fluoro-silicone acrylate). Thus, it is preferred for the crosslinked polymer material of the optical isolating coating to be a polymer preferably based on acrylate, urethane acrylate, or even silicone, silicone acrylate, the polymer also having a fluorinated function.

[0259] The optical isolating coating according to the invention may in particular be a coating obtained by liquid means and obtained from a formulation preferably photocrosslinkable by ultraviolet UV (in particular UVA) or even a two-component crosslinking by chemical reaction. Crosslinking by UV(A) is preferred because crosslinking is faster and the equipment less expensive / more compact than by chemical reaction.

[0260] In a first example of an optical isolating coating, a crosslinkable UV resin based on acrylates is deposited on the first polymer film.

[0261] In a second example of an optical isolating coating, a single-component, crosslinkable UV resin based on acrylates (urethane acrylate) is deposited on the first polymer film. In a third example of an optical isolating coating, a crosslinkable, silicone-based UV resin is deposited on the first polymer film. The optical isolating coating (clear or tinted) may comprise, or even consist of, a matrix with a refractive index n2 m greater than n2 and less than n1 or n'1, and with preference n2 m of at most 1.48 and n2 preferably of at most 1.42, and comprising (nano)porosities and / or low index (nano)particles, in particular hollow ones, of size (external diameter) of at most 300nm or even of at most 100nm, for example hollow silica nanoparticles. Preferably, the optical insulating coating is free of free silicone, of volatile silicone component (source of surface pollution).

[0262] The matrix may be organic, in particular a crosslinked polymer or thermoplastic, in particular chosen from polymer based on polyacrylate, polyepoxides, polyvinyl acetate, polyester, polyurethane, PVB or the matrix is ​​mineral, in particular silica.

[0263] We can cite the already described low index polymers if we want to lower n2 further.

[0264] The optical isolating coating comprises in particular at most 60% in volume fraction of (nano)porosities and / or low index (nano)particles or one of the following values: 40, 45%, 40%, 35%, 30%.

[0265] For example, the matrix of the optical isolating coating is a polymer and the matrix of the diffusing coating (in contact or even deposited on the optical isolating coating) is a chemically compatible polymer (identical or similar polymer).

[0266] For example, the matrix of the optical isolating coating is a polyacrylate polymer and the matrix of the diffusing coating (in contact or even deposited on the optical isolating coating) is a polyacrylate polymer.

[0267] For example, the matrix of the optical isolator coating is a polymer and a protective coating (in contact or even deposited on the optical isolator coating) is a chemically compatible polymer (identical or similar polymer).

[0268] For example, a protective coating (in contact or even deposited on the optical isolating coating) is a polymer (polyacrylate etc.) and the matrix of the diffusing coating (in contact or even deposited on the protective coating) is chemically compatible (identical or similar polymer, in particular polyacrylate polymer).

[0269] In a second configuration, the optical isolator layer is a fluoropolymer film with Ep preferably at most 100 pm, preferably corona treated, preferably the interlayer material of the trilayer (of the lower interlayer, the first interlayer), and even of an interlayer frame), is based on PVB, preferably with a peel strength between the fluoropolymer film and the lower interlayer (and preferably between the first film and the first interlayer) of at least 2 N / mm and even at least 3 N / m.The fluoropolymer film may be based on or made from one of the following materials: perfluoroalkoxy PFA, in particular with an index of approximately 1.3, poly(vinylidene fluoride) PVDF, in particular with an index of approximately 1.4, ethylene Chlorotrifluoroethylene ECTFE, ethylene tetrafluoroethylene ETFE, more precisely poly(ethylene-co-tetrafluoroethylene, in particular with an index of approximately 1.4, perfluorinated ethylene propylene copolymer FEP or (Fluorinated Ethylene Propylene in English) in particular with an index of approximately 1.3 or polytetrafluoroethylene PTFE in particular with an index of approximately 1.3, polyvinyl fluoride (Polyvinyl Fluoride or PVF).

[0270] The light extraction layer can in particular be:

[0271] - a diffusing coating (matrix with diffusing particles) which is on the optical isolating coating with a possible protective overlayer (dense) of the optical isolating coating (porous etc.) or which is on the lower interlayer.

[0272] Preferably the diffusing coating:

[0273] - is a hard coat, thanks to its matrix, in particular which is not likely to be damaged during lamination (by calender) of the laminate,

[0274] - is not likely to stick (to the calender, to the roller of a roll-to-roll process, etc.), for example a varnish (anti-stack).

[0275] For example, the diffusing coating has a hardness H of at least 1 H.

[0276] In particular, the lower interlayer may be PVB-based with 0% to 20% or at most 15% or 10% or 5% plasticizers, with Ei possibly of at most 50 pm. It may carry the diffusing coating on the main front or back face or be in contact with the diffusing coating on the optical isolating coating.

[0277] The laminate may comprise the laminated trilayer or even comprise a laminated multilayer with at least 4 or 5 laminated layers (in adhesive contact with each other), preferably at least 1 third interlayer or at most 2 additional interlayers, 1 transparent functional film (electroconductive, passive, sandwiched between two interlayers) or at most 2 transparent functional films (electroconductive, passive, sandwiched between two interlayers) and / or an electroactive element (in particular based on all-solid electrochromic).

[0278] In particular, the laminated multilayer comprises:

[0279] - the three-layer (linked to a possible frame)

[0280] - a functional polymer film, for example a solar control film (for example with an electroconductive coating, solar control or coextruded film etc.) or an all-solid electrochromic element (comprising an electrochromic system between two substrates carrying electroconductive layers forming electrodes, for example a polymer film with an electrode)

[0281] - a third interlayer of lamination.

[0282] Any electroactive element capable of undergoing lamination by a calender can be included in the laminated laminate (rather an electroactive element in sheet form upstream of the calender or resulting from the unwinding of a roll). In particular, the electroactive element comprising a first thermoplastic film (or even thin glass called "UTG" in English, with a thickness of at most 0.3 mm), in particular polyester (in particular PET, preferably at most 0.3 or 0.2 mm etc.), with a first (transparent) electroconductive layer, for example a transparent layer of oxide(s) (TCO in English) such as indium tin oxide (ITO), or even a silver stack etc., an all-solid technology electrochromic layer / a second thermoplastic film (or even thin glass UTG in particular with a thickness of at most 0.3 mm), in particular polyester (PET, at most 0.3 or 0.2 mm etc.), with a second electroconductive layer (TCO such as ITO, silver stack etc.).

[0283] The laminate may comprise a laminated three-layer or even a multi-layer with at least 4 or 5 layers, preferably at most 1 or 2 additional interlayers, an electroactive element (in particular based on liquid crystals or electrochromic or even photovoltaic).

[0284] In particular, the multilayer includes:

[0285] - the laminated three-layer (linked to a possible frame)

[0286] - an electroactive element (with another possible frame)

[0287] - a third interlayer (upper interlayer), attached to the three-layer.

[0288] It is preferable to avoid lamination by calendering for certain electroactive systems, particularly those based on liquid crystals or solar cells.

[0289] The laminated functional laminate may comprise a lamination interlayer frame on the periphery of the trilayer (of the multilayer) and locally in adhesive contact with the trilayer. The laminated functional laminate may comprise at least one light redirection element (as already described), in particular with a thickness Er < 200 pm and even at most 150 pm and better still at least 70 pm and in particular the interlayer material (of the trilayer and / or an interlayer frame integral with the trilayer, preferably based on PVB, plasticized or even partly without plasticizer) is locally in adhesive contact with the light redirection element.

[0290] The cut laminate may have a protruding frame surface filled by an interlayer frame of variable color, possibly opaque over all or part of its thickness.

[0291] The laminate may also include a masking layer, for example an ink (printed) which is opposite the light redirection element to prevent stray light from escaping on the F1 side, passing through the (imperfect) reflective film.

[0292] The intermediate frame carrying the light redirection element may comprise an opaque zone (in mass, for example black PVB, or black coating) opposite the light redirection element, between the prisms and the F2 face.

[0293] The laminate carrying the light redirection element may include an opaque area (opaque coating, black ink) opposite the light redirection element, between the prisms and the F2 face.

[0294] The invention also relates to a roll comprising the functional laminate (rolled) as described above (before its cutting), thus including at least the laminated three-layer, laminate with a width of at least 600 mm, and / or a length of at most 300 or 500 mm and possibly comprising a temporary protective film. Finally, the invention relates to a method for manufacturing a functional laminate which comprises forming a roll of said laminate as described above, a roll method.

[0295] This involves the manufacture of the layers of the trilayer for example:

[0296] - an extrusion of the first interlayer (in sheet),

[0297] - an extrusion of the lower interlayer (in sheet, for example plasticized PVB, usual) self-supporting or on a possible carrier substrate (temporary etc.), or a liquid deposition of the lower interlayer (for example little or not plasticized PVB) on a carrier substrate (temporary etc.),

[0298] - the formation of the insulating coating on the first coated film preferably in line (roll or roll for example).

[0299] This also involves depositing the diffusing coating preferably in line (roll to roll for example).

[0300] Forming a roll of said laminate may involve:

[0301] - a continuous roll-to-roll process, starting from several rolls of sheets up to the laminate roll, therefore a single roll-to-roll process

[0302] - a roll process resulting from several roll-to-roll processes in succession and / or the formation of rolls from extrusion(s).

[0303] Preferably the speed is at least 1 or 10 or 20m / min.

[0304] Thus the invention aims at the formation of a roll of functional laminate, in particular a roll-to-roll method, comprising:

[0305] - a first continuous printing of the optical insulating layer in strip form, with said first thermoplastic film having a main rear face with a roughness Rz of at most 50 pm (and a front face, for example, with a roughness Rz of 50 pm or more), which is a first fluoropolymer film or preferably a first thermoplastic film, in particular polyester (preferably PET), bearing an optical insulating coating (for example a hard layer or "hard coat" in English or even with a hard, transparent protective coating, compatible with the lower interlayer),

[0306] - a second continuous print of the first interlayer in strip form, and in sheet form, having a smooth rear face with a roughness Rz of at most 50 pm (and a front face with a roughness Rz of, for example, 50 pm or more), preferably a second print separate from the first print (first interlayer and optical isolator layer are two independent strips, running separately)

[0307] - a third continuous print run of the lower interlayer in a strip (in an independent sheet, or lower interlayer on the first film, laminated to the first film or coating on the first film in a strip) having a smooth front face with a roughness Rz of at most 50 pm (and a rear face with a roughness Rz of, for example, 50 pm or more), in particular a third print run separated from the second print run (two independent strips) or associated with the second print run (lower interlayer on the first film, forming a composite strip, two-layer)

[0308] - heating of the first interlayer (with a temperature adjusted according to the interlayer material),

[0309] - heating of the lower interlayer (independent strip or composite strip), (with a temperature adjusted according to the interlayer material) when the third print is separated from the second print, the light extraction layer being on the lower interlayer or on the optical isolator layer in the form of a diffusing coating (in particular organic matrix with diffusing particles), in one or more diffusing patterns preferably with a coverage rate of at most 30%,

[0310] - the formation of the laminated laminate by calendering (pressing by passage between two counter-rotating cylinders with adjusted spacing), in this order of the first heated interlayer, the first film, the lower interlayer possibly heated (independent sheet),

[0311] - winding the laminated material onto a roller called a winder.

[0312] It is preferable to produce laminated laminates using a roller process rather than sheet-to-sheet assembly followed by autoclave lamination to improve the handling of thin films in the roof manufacturing stages, limit the risk of pollution on thin films, limit folds, for less waste.

[0313] It is also preferable to use one or more rolls rather than pre-cut sheets conveyed before the calender.

[0314] The method of forming a roll may further comprise inserting into the calender (to form the laminate):

[0315] - a third interlayer, in sheet form, from another roll, with preheating (upstream of calendering),

[0316] - an electroactive (electro-optical) element, such as an all-solid-state electrochromic element, in strip form (from a roll) or in cut sheet, or a functional polymer film

[0317] - or a laminated functional bilayer comprising a third interlayer in adhesive contact with an electroactive element or a functional polymer film (thermoplastic, in particular polyester, PET). preferably in this order: the third interlayer (independent sheet) optionally heated, the electroactive element or the functional polymer film, the first heated interlayer, the first film, the lower interlayer (optionally heated, independent sheet) or the laminated functional bilayer, the first heated interlayer, the first film, the lower interlayer (optionally heated, independent sheet). The heating of the interlayer material serves to make the interlayer sticky for adhesion with the first film (with or without an optical insulating coating, diffusing coating) or other film (non-adhesive, PET, etc.),

[0318] - in particular if based on PVB (plasticized), the heating of the first interlayer is preferably at least 50°C or 60°C and at most 120°C

[0319] - in particular if based on PVB (plasticized or not), the possible heating of the lower interlayer is preferably at least 50°C or 60°C and at most 120°C

[0320] - in particular if based on PVB (preferably plasticized, usual PVB), the possible heating of the third lower interlayer is preferably at least 50°C or 60°C and at most 120°C.

[0321] Calendering, preferably at room temperature, is most rapid after heating, e.g. less than 10s or 5s.

[0322] Cooling of the functional laminate in strip form (after calendering) can be provided before winding, for example by passing it over a cooled roll(s).

[0323] The method of forming the roll may comprise the insertion of a temporary protective polymer film (non-stick), for example polyethylene (PE), strip unwound from a roll (of PE) before winding so that the free face of the outermost interlayers (preferably based on PVB) of the laminate (lower interlayer, and for example first interlayer or third interlayer) are not in contact with each other, are separated by the temporary protective polymer film.

[0324] To make the unwinding of the strips more reliable, swelling mandrels can be used.

[0325] The rollers of the calender can be metallic, polymer (rubber) or one metal, the other polymer (rubber).

[0326] The faces of the first interlayer and the lower interlayer intended to be in adhesive contact with the first film after lamination are preferably smooth.

[0327] The face of the lower interlayer coated with a diffusing coating is preferably smooth.

[0328] The extraction layer can be a hard coat with sufficient hardness (at least 1 H) to be in contact with the calender.

[0329] Apart from temperature, the parameters of a roll process (or even strips from extruder(s) and a possible roller) include the following:

[0330] - the tension (in N / m) of the first interlayer (possibly single-layer or multi-layer, for example acoustic PVB), the tension (in N / m) of the first film, or even the tension (in N / m) of the lower interlayer, controlled so as to unwind correctly, maintaining sufficient tension to ensure that the strip is held securely over the entire width, while avoiding elongation of the material(s). - and / or the tension (in N / m) of a first film / lower interlayer bilayer (or first film / first interlayer) controlled so as to unwind the bilayer correctly, maintaining the tension to ensure that the strip is held securely over the entire width, while avoiding elongation of the material(s).

[0331] - the (linear) pressure applied by the calender, preferably at most 3500 N / m.

[0332] We can provide for (retro)control of the voltages, the heating(s), the pressure

[0333] Several rollers can be used before and after the calender, in particular:

[0334] - to tension and avoid creases one or more guide rollers (number depending on the material), in particular one guide roller for the first film (if PET in particular), one or more (three) guide rollers for an interlayer of lamination (PVB in particular).

[0335] Heating can be done by:

[0336] - IR infrared lamp (for example IR absorbing sheet material, generating heating), in particular a plurality of IR lamps (tubes etc.) transverse to the direction of draw across the width of the strip in question, in particular IR resistors,

[0337] - hot air

[0338] - microwave

[0339] - passage between heated rollers.

[0340] In particular, the roll forming process includes a total pre-cutting on one or both free edges of the strip after calendering and before winding, and even followed by a lateral cutting to move, store, transport the winding roll.

[0341] In one configuration the three aforementioned prints (optical isolator layer, first interlayer, lower interlayer) are distinct.

[0342] In an alternative configuration, the lower interlayer or the first interlayer is already laminated with the optical isolator layer (thus there are only two distinct prints among the three prints mentioned above before calendering for the trilayer).

[0343] In a first embodiment, the roll forming process (is roll to roll) and comprises for the (three) prints:

[0344] - (for the first print run) the unwinding of a roll called the first interlayer roll comprising the first interlayer layer in strip form

[0345] - (for the second print run separate from the first print run) unwinding a roll called an insulating roll comprising the optical insulating layer (low index) with said first thermoplastic film in strip form, the first thermoplastic film preferably carries on the rear face the optical insulating coating and the light extraction layer which is on the optical insulating coating

[0346] - (for the third print run separate from the first and second print runs), the unwinding of a roll called the lower interlayer roll comprising the lower interlayer layer in a strip preferably based on PVB with at least 20% plasticizer, with a thickness Ei of at least 0.3 mm.

[0347] Alternatively, unwinding a roll called lower interlayer roll comprising the lower interlayer layer in strip lower interlayer roll, the lower interlayer layer is based on PVB of at most 10% or 5% or 1% of plasticizer having a main face for bonding with the first film and a face opposite the bonding face. The main bonding face is provided with the light extraction layer (diffusing coating) or the opposite face is provided with the light extraction layer preferably hard layer with a hardness of at least 1 H.

[0348] And even the coverage rate of the diffusing coating is preferably at most 25% or 10% when the extractor face is intended to be the rear face, extractor face possibly in contact with the calender.

[0349] The coverage rate can be limited to promote cohesion of the laminate and lamination with the glass.

[0350] In particular if Ei is less than 50 pm, the lower interlayer is preferably bonded with a sacrificial polymer sheet on the main front or rear face of the lower interlayer called the bonding face opposite the extracting face, sacrificial polymer sheet secured electrostatically (low adhesion) and removed before calendering.

[0351] It depends on the winding on the lower interlayer unwinding roller, the light extraction layer can be in contact with the calender or optical isolator layer side.

[0352] In a second embodiment, the roll forming process (is roll to roll) and comprises (for prints):

[0353] - (for the first print run) the unwinding of a roll called the first interlayer unwinding roll comprising the first interlayer layer (31) in strip form, preferably which is based on PVB with at least 20% plasticizer

[0354] - (for the second print run separate from the first print run and associated with the third print run) the unwinding of a composite roll called an insulating roll, comprising a laminated bilayer comprising the optical insulating layer with said first thermoplastic film, in strip form and the lower interlayer (sheet or coating) which is based on PVB with at most 5% or 1% of plasticizer, with a thickness Ei of at most 80 pm, having a main face for bonding with the first film and a face opposite the bonding face, the light extraction layer is on the bonding face or the opposite face (then preferably a hard layer with a hardness of at least 1 H).

[0355] - said calendering of the bilayer and the first interlayer.

[0356] The method of forming a roll of the laminate may comprise (upstream of the second draw, the formation of the insulating roll): - the unwinding of a primitive roll comprising the first thermoplastic film in strip form, in particular a primitive draw of said first thermoplastic film in strip form

[0357] - the liquid deposition of a composition called an insulating composition to form the optical insulating coating, preferably during said initial drawing, in particular comprising a porous matrix (organic or mineral, in particular silica) and / or with hollow (nano)particles (in particular silica)

[0358] - a possible liquid deposition of a hard protective overlayer (in particular the dense matrix and / or without hollow nanoparticles)

[0359] - the liquid deposition on the optical insulating coating (directly or on the overlayer) of a composition called an extracting composition comprising a matrix, in particular organic, crosslinkable (photo or thermocrosslinkable) and diffusing particles, forming one or more patterns, to form the light extraction layer (after hardening, crosslinking) in particular during said initial printing or in resumption during a following printing

[0360] - possible winding of the first film with the optical insulating coating and the light extraction layer in a winding roll, unwinding roll for the second run. Due to the relaxation of the interlayer material (PVB with little or no plasticizer), the deposition of the insulating composition and the deposition of the extracting composition takes place (at room temperature) - before the heating, calendering process

[0361] The main known techniques for depositing a liquid composition are:

[0362] - by flow,

[0363] - by spraying (flow coating),

[0364] - by immersion (dip coating in English),

[0365] - by screen printing,

[0366] - by digital printing or inkjet.

[0367] In particular, it is possible to deposit a spin coating, or with a film puller, by curtain or via a flat die (slot die in English) which has an outlet slot nozzle (rectilinear etc.), with a Meyer bar or by gravure printing.

[0368] In one embodiment, the deposition is by means of a Mayer bar, consisting of a cylindrical core surrounded by a spiral. The thickness of the deposit depends essentially, in a known manner, on the spacing of the turns and the diameter of the rod constituting these turns, that is to say on the depth of the cylindrical core in relation to the (external) contact surface of the turns. A controlled thickness of the liquid deposit is obtained.

[0369] In a roll (or roll-to-roll) process, the preferred method is to deposit the insulating composition by flat die, by gravure roll, or with a Meyer bar.

[0370] The method of forming a roll of the laminate may comprise: - unwinding a primary roll comprising said first thermoplastic film in a strip with, in particular, on the rear face the optical insulating coating, and possibly the lower interlayer (coating or sheet)

[0371] - or the extrusion of the lower interlayer, in particular in strip and sheet form,

[0372] - or the unwinding of a primary roll comprising the lower interlayer in strip form, lower interlayer based on PVB with at most 5% plasticizer, with a thickness Ei of at most 80 pm.

[0373] And it is followed by the liquid deposition on the optical insulating coating in strip form or on the lower interlayer (rear or front face) in strip form of a composition comprising a matrix, in particular organic, crosslinkable (by UV in particular, photo or thermocrosslinkable) and diffusing particles layer in one or more patterns, to form the extraction layer.

[0374] Due to the relaxation of the interlayer material (PVB with little or no plasticizer), the deposition of the extractant composition takes place (at room temperature) before the calendering and even preheating process.

[0375] The extraction layer can be carried either by the first film (possibly already with an insulating layer in the form of an optical insulating coating), or by the lower interlayer (PVB-based).

[0376] The deposition of the extractant composition preferably takes place in a clean environment so as not to trap particles (during hardening).

[0377] Among the preferred techniques for depositing the extractant composition we can cite: flexography, gravure printing, inkjet printing.

[0378] In the present invention, the light transmission TL (in %) and the haze (in %) are, for example, measured according to the ASTM D 1003 standard.

[0379] Other details and advantageous characteristics of the invention will appear on reading the examples according to the invention illustrated by the following figures.

[0380] Figure 1 represents a schematic sectional view of an illuminable laminated glass roof 100 of a motor vehicle according to the invention in a first embodiment. Figures 1a and 1b describe the main steps of manufacturing this illuminable laminated roof 100.

[0381] Figure T represents a schematic sectional view of an illuminable laminated glass roof 100' of a motor vehicle according to the invention in a variant of the first embodiment. Figure Ta describes steps in the manufacture of this illuminable laminated roof 100'.

[0382] Figure 2 represents a schematic sectional view of an illuminable laminated glass roof 200 of a motor vehicle according to the invention in a second embodiment. Figure 2a describes a step in the manufacture of this illuminable laminated roof 200.

[0383] Figure 2' represents a schematic sectional view of an illuminable laminated glass roof 200' of a motor vehicle according to the invention in a variant of the second embodiment. Figure 3 represents a schematic sectional view of an illuminable laminated glass roof 300 of a motor vehicle according to the invention in a third embodiment. Figure 3a describes a step in the manufacture of this illuminable laminated roof 300.

[0384] Figure 3' represents a schematic sectional view of an illuminable laminated glass roof 300' of a motor vehicle according to the invention in a variant of the third embodiment.

[0385] Figure 4 represents a schematic sectional view of an illuminable laminated glass roof 400 of a motor vehicle according to the invention in a fourth embodiment. Figure 4a describes a step in the manufacture of this illuminable laminated roof 400.

[0386] Figure 5 represents a schematic sectional view of an illuminable laminated glass roof 500 of a motor vehicle according to the invention in a fifth embodiment. Figure 5a describes a manufacturing step of this illuminable laminated roof 500 and manufacturing alternatives in Figures 5b, 5c, 5d, 5e.

[0387] Figure 6 represents a schematic sectional view of an illuminable laminated glass roof 600 of a motor vehicle according to the invention in a sixth embodiment. Figure 6a describes a step in the manufacture of this illuminable laminated roof 600.

[0388] Figure 7 represents a schematic sectional view of an illuminable laminated glass roof 700 of a motor vehicle according to the invention in a seventh embodiment. Figures 7a and 7b describe steps in manufacturing this illuminable laminated roof 700 and Figures 7c, 7d, 7e, 7f are manufacturing variants.

[0389] Figure 7' represents a schematic sectional view of an illuminable laminated glass roof 700' of a motor vehicle according to the invention in a variant of the seventh embodiment.

[0390] Figure 8 represents a schematic view of a method of forming the functional laminate roll in a first configuration of the invention, roll-to-roll method with in figures 8' and 8” variants of functional laminate according to the invention which can be obtained.

[0391] Figure 9a shows a schematic view of a method of forming a roll used for manufacturing the functional laminate in a first configuration of the invention, a roll-to-roll method.

[0392] Figure 9b shows a schematic view of a method of forming a roll used for manufacturing the functional laminate in a second configuration of the invention, a roll-to-roll method.

[0393] Figure 10 shows a schematic view of a method of forming the functional laminate roll in a second configuration of the invention, a roll-to-roll method.

[0394] Figure 11 shows a schematic view of a method of forming the functional laminate roll in a third configuration of the invention, a roll-to-roll method with in figures 1 T and 11 ”variants of functional laminate according to the invention that can be obtained.

[0395] 37

[0396] RECTIFIED SHEET (RULE 91) ISA / EP Figure 1 represents a schematic sectional view of an illuminable laminated glass roof 100 of a motor vehicle according to the invention in a first embodiment, with (in magnifying glass) a detailed view of the reflective prismatic film used to redirect the light and a detailed view of electroactive element 9 (optional).

[0397] In particular, for a fixed roof (canopy) the width is from 85cm to 1.4m and the length from 75cm to 1.65m.

[0398] This is a laminated car roof 100, (generally) rectangular and curved (in one or more directions), which includes:

[0399] - a first sheet of glass 1, for example rectangular (of dimensions 1600X1100 mm for example of thickness equal to 2.1 mm for example), with a first main face 11 corresponding to face F1 a second main face 12 called face F2 and an edge (longitudinal slices 10 and 10'), the glass 1 being clear (Planiclear for example of TL 91%) with the face F2 coated with a low emissive functional coating called low E (silver stacking etc.) the whole having for example a TL 71.8%) or alternatively glass 1 with a tinted composition (VENUS VG10 or TSA 4+ glass marketed by the company Saint-Gobain Glass with light transmission or TL of approximately 28%)

[0400] - a second transparent sheet 2, preferably mineral glass, here of the same shape and dimensions as the first sheet 1, forming internal glazing, on the passenger compartment side, having a third main face 13 or face F3 and a fourth main face 14 or face F4, and an edge (longitudinal slices 20 and 20' - for example a sheet of sodium-calcium silico glass, extra-clear such as Diamant glass marketed by the company Saint-Gobain Glass with a TL of at least 91%, of thickness equal for example to 2.9 mm, glass 2 with a refractive index n1 of the order of 1.52 at 600 nm or Optiwhite glass of 1.95 mm or Sunmax glass of 2.05 mm.

[0401] - between the face F2 12 and the face F3 13, a lamination interlayer 3, transparent, with an edge (out or part) aligned or possibly set back from the glasses 1, 2, multi-layer lamination interlayer, preferably thermoplastic (and even PVB), here comprising:

[0402] - a first interlayer, here central, 31, thermoplastic, preferably based on plasticized PVB (usual) with at least 20% or 30% by weight of plasticizers - for example tinted, gray, TL at 27%, 0.38mm thick or 0.76mm (in one or two sheets possibly with an indistinguishable interface)

[0403] - a second intermediate layer called lower 32, thermoplastic, preferably based on PVB (here with plasticizers, for example at least 10% or 20% or 30% by weight of plasticizers, in particular at most 30% or 20% by weight), clear (as transparent as possible and with as few optical defects as possible), for example 0.38 mm, in adhesive contact with the face F3, with a refractive index n3 of approximately 1.48 at 600 nm, for example with a TL equal to 99.9%,

[0404] - a third intermediate layer called upper 33, thermoplastic, here preferably based on plasticized PVB (at least 20% or 30% by weight of plasticizers), for example 0.38mm or 0.76mm (in one or two sheets), in adhesive contact with the face F2, third intermediate layer clear or in a tinted variant, for example gray, of TL equal to 27%.

[0405] Alternatively, the lower interlayer 32 is based on PVB with little or no plasticizers (in particular less than 5% by weight of plasticizers), for example with a thickness of at least 20 pm or 30 pm and at most 80 pm.

[0406] The laminated glass roof 100 comprises an internal masking layer 7 forming a masking frame delimiting a window clear 70 (daylight) here (generally) rectangular for example with straight edges. Any local modification of the edges 70 is possible (gradient of points, wider zone etc). For example:

[0407] - the internal masking layer 7 is a black enamel on the F2 face

[0408] - or the internal masking layer 7 is a black ink, on one of the faces of the upper interlayer 33, preferably the face facing the face F2, ink preferably based on PVB with black pigments,

[0409] - the masking width at the front (front side edge) is for example 10 to 40cm

[0410] - the masking width at the rear (rear side edge) is for example 5 to 25cm

[0411] - the masking width on the long sides (longitudinal edges) is for example 5 to 20cm, identical or different width for the two long sides.

[0412] To optically isolate the lower part with light guide and light extraction and the tinted, absorbent upper part, the laminated glass roof 100 further comprises an optical isolating layer which here comprises an optical isolating coating 5 with a refractive index n2 <n1 , de préférence sur la face arrière (orientée côte face F3) d’un premier film transparent 5’, de préférence polymère et même thermoplastique (non adhésif au verre notamment, par exemple polyester, PET). Alternativement la couche isolateur optique est un premier film transparent fluoropolymère avec un indice de réfraction n2<n1.

[0413] The optical insulating layer (here first film 5' coated with layer 5) is sandwiched between the first interlayer 31 and the lower interlayer 32 (and even in adhesive contact), extends throughout the clear glass and preferably beyond, its edge being under the masking layer 7, preferably set back from the glasses 1, 2.

[0414] To simplify and make manufacturing more reliable, the first interlayer 31 / optical isolator layer / lower interlayer 32 assembly (of similar dimensions) was pre-laminated (by calendering). Then, the lower interlayer 32 was partially cut, leaving a protruding frame surface 3T of the first interlayer 31.

[0415] A thermoplastic lamination interlayer frame 34, preferably based on plasticized PVB (with at least 30% by weight of plasticizers), is on the periphery of the cut lower interlayer layer 32 (and in adhesive contact with it) and the optical isolator layer 5.5' is in adhesive contact with the frame surface 3T and the face F3 13. The optical isolator layer (and even the first film 5') is here of thickness less than 200 pm or even at most 100 pm and is protected at the periphery by the interlayer frame 34.

[0416] The first interlayer 31 and the frame 34 may be set back from the edges 10, 10', 20, 20' of the glasses 1, 2 in particular by at least 10 mm.

[0417] The optical isolating coating 5 is made of material, preferably polymer, comprising a matrix, in particular distinct from a fluoropolymer, of submillimeter thickness, of at least 400nm and better of at least 500nm or 800nm ​​or 1 pm, and a slice 50 possibly set back from the slice of the first film 5' without harming the optical isolation function. The optical isolating coating 5 can be directly on the first film 5' or on a functional sub-layer (barrier etc.), transparent on the first film 5'. The optical isolating coating 5 is transparent and even as transparent as possible.

[0418] The first 5' film is transparent but can be tinted.

[0419] In one configuration, the optical isolating coating 5 comprises a crosslinked polymer matrix with said index n2, preferably at most 1.42 and optionally at least 1.35, matrix preferably among polymers based on polyacrylate with fluorinated function, in particular urethane acrylate or fluoro urethane acrylate or fluoro-silicone acrylate. The thickness is preferably at most 10 pm or 5 pm or 2 pm and at least 800 nm.

[0420] In one configuration, the optical isolator coating 5 comprises a matrix with a refractive index n2 m greater than n2 and less than n1, and preferably with n2 mof at most 1.48 (and n2 preferably of at most 1.42 and optionally of at least 1.35), and comprising (nano)porosities and / or (nano)particles of low index (refractive index less than n 1 ), in particular hollow, of size preferably of at most 300nm or even 100nm, for example hollow silica nanoparticles. The thickness of the optical isolating coating is preferably of at most 10pm or 5pm and of at least 800nm.

[0421] More broadly, the matrix may be a crosslinked polymer or thermoplastic, in particular chosen from a polymer based on polyacrylate, polyepoxides, polyvinyl acetate, polyester, polyurethane, PVB or mineral, in particular silica. The polymer matrix based on polyacrylate, polyurethane or even polyepoxides, polyvinyl acetate or polyester is preferred. Alternatively, the optical isolating coating 5 is porous silica.

[0422] In order to avoid folds, undulations, preferably the optical isolator layer 5, 5' may be in an area of ​​the roof having a curvature, a sphericity limited in particular by a radius of curvature of at least 1.5 m. For example, the edge of the first film 5' may be sufficiently far from the edge of the sheets 1, 2. The masking width on the sides and / or front and rear may be adjusted (increased) for this purpose.

[0423] For example, the first transparent film 5' is a clear PET with a TL of approximately 90% or more (or tinted and even opaque), of less than 200pm, in particular 100pm or 75pm. For the light function, the laminated glass roof 100 further comprises, masked from the outside by the internal masking layer 7:

[0424] - one or two groups of light-emitting diodes 4,4' (here with front emission or "top emission"), in the form of rectilinear bars on a support 40, 40' (for example printed circuit board, called 'PCB') opposite (or offset) the fourth main face F4 14, and even integral with the face F4

[0425] - on the third main face F3 side, first and second peripheral light redirection elements, each forming a reflective prismatic film 8.8' comprising a textured main face with reflective prisms and an opposite main face called the smooth face.

[0426] For example, as shown in detail, each reflective prismatic film 8 comprises a polymer prismatic film, for example 125 pm thick, with:

[0427] - a flat part or base 81 (substrate for example polyester, PET in particular of at most 100 pm) in adhesive contact with the first interlayer 31 (with the frame surface 3T)

[0428] - and a textured layer (embossment of a resin, for example polyacrylate crosslinked for example by ultraviolet UV etc.), partially or even entirely textured, forming prisms 82 which have become reflectors by a reflective layer 83 for example metallic (by conformal deposition on the prismatic textured surface), here reflector prisms oriented towards the face F3.

[0429] Here each prismatic reflective film 8 is in adhesive contact with the frame surface 3T (by the base 81) and with the front face of the interposed frame 8. With this orientation of the films, the base 81 can be tinted, opaque to mask stray light.

[0430] The microprisms are schematically in section in the form of right triangles but the angle at the apex can be adjusted to better redirect towards the extraction means 6. In the same way the main direction of emission of the diodes 4 can be adjusted (normal or inclined relative to the face F4).

[0431] The reflective prismatic films form, for example, two longitudinal strips on either side of the glass clear, opposite each 4.4' diode bar.

[0432] Alternatively, the prismatic film 81, 82 is a monolithic polymer film, for example preformed, coated with the reflective layer 83.

[0433] The light from the diodes 4, 4' is refracted in the second glass 2, in the reflecting prismatic film 8 and then redirected at a given angle towards the third face F3. The light rays propagate by total internal reflection to light extraction means (via the surface on the face side F3) in the form of a diffusing coating in one or more patterns 6, for example diffusing ink and as transparent as possible if desired, and in the clear glass here on the optical isolating coating 5 (for example printed on it).

[0434] In particular, one can have a collimator between the (each) light source and the fourth face F4, in particular an optical element fixed to the fourth face F4. The light source can be fixed to the fourth face F4. The collimator generates a light beam from the beam

[0435] 41

[0436] SUBSTITUTION SHEET (RULE 26) generally diverging light from the light source with a preferably essentially parallel beam path, or at least a less divergent, i.e. more focused, beam path. The beam cone of the light source is thus narrowed by the collimator. The main direction of radiation from the light source can be adjusted, for example, to form an angle with the normal of the glazing, for example, at 22° to the normal to the glazing.

[0437] The collimator can be made of glass or transparent plastic, particularly polycarbonate (PC) or polymethyl methacrylate (PMMA). A separate collimator can be provided for each light-emitting diode. However, it is preferable to use a common collimator for the entire diode arrangement. For example, in the case of a linear diode array (especially a longitudinal diode strip), a collimator can be used whose length is at least equal to the length of the diode array.

[0438] The reflective prismatic films 8 are attached to the first film 5', and even to the optical isolating coating 5, or spaced at most 4mm apart to avoid light leakage. As a precaution to avoid stray light passing through the prismatic film 8 (in particular clear or lightly tinted base) and even the masking layer 7, an internal opaque element is optionally added to the right of each prismatic film 8 (of the same width and not exceeding the internal edge 80' of the prismatic film 8).

[0439] Alternatively, one or more transparent prismatic films are chosen on the F4 side, downstream of the diodes. The diodes 4, 4' and / or their support can be secured to the F4 side (by an additional part, by direct gluing, etc.).

[0440] Alternatively, the diodes 4, 4' are side-emitting.

[0441] In particular, it is possible to have (on each side of the viewport) a set of diode strips (bands) on supports 40 that are separate or connected to each other, preferably aligned. It is also possible to place (alternatively or cumulatively) diode strips on the front or rear edges (on each side of the viewport).

[0442] The longitudinal edges 10, 10' here are not necessarily parallel.

[0443] The diffusing patterns 6 are for example extended or point geometric patterns.

[0444] For example, the distance between the diffusing coating 6 and the diodes (or the prismatic film 8 or 8') is at least 10mm or 40mm.

[0445] For example, the diffusing coating is with an acrylate matrix, preferably with a refractive index greater than or equal to n1, with TiO2 particles of at least 100nm in diameter and preferably at most 1 pm or 400nm. The diffusing coating is for example 10pm to 100pm or even 50pm thick.

[0446] The diffusing coating (e.g. matrix, such as a resin, with diffusing particles, such as TiO2, 100 to 200nm in diameter) can be deposited on the back face of the PVB 32 facing the F2 face or on the optical isolator coating 5. For example, the

[0447] 42

[0448] SUBSTITUTE SHEET (RULE 26) diffusing coating (a diffusing pattern or network of patterns, disjointed and / or interconnected) in contact with the optical isolating coating preferably covers at most 50% or 40% of the glass clear to promote adhesion of the optical isolating coating with the lower interlayer 32.

[0449] Alternatively, the diffusing coating (diffusing pattern or network of patterns, disjointed and / or interconnected) is in contact with the face F3 and preferably covers at most 40% of the clear glass to promote adhesion with the second sheet 2. The diffusing coating is preferably deposited on the main rear face of the lower PVB layer 32, facing the face F3. The diffusing coating 6, comprising a polymer or mineral matrix, is deposited by liquid means (by ink jet, screen printing, etc.). The diffusing coating is alternatively deposited on the face F3, for example an enamel.

[0450] You can choose diodes emitting white or colored light for ambient lighting, reading lighting, etc.

[0451] It is possible to provide several series of 4 diodes (one edge, two edges, three edges, on the entire periphery) controlled independently and even of different colors.

[0452] An infrared-reflecting coating 17 on the F4 face forms a low-emissivity layer (in particular an ITO multilayer, in particular ITO between two layers of metal oxide and / or nitride and / or Si).

[0453] The roof 100 comprises between the upper interlayer 33 and the first interlayer 31, an electroactive (electro-optical) device 9, here with variable diffusion (or even variable tint), in particular based on liquid crystals for example PDLC with or without dichroic dye or even GH. The device 9 is even in adhesive contact with the upper interlayer 33 and the interlayer 31.

[0454] The thickness of the device being for example of the order of 0.4 mm, another intermediate frame 35 is added, for example of thickness 0.38 mm, based on plasticized PVB, clear or tinted. The edges of the device 9 are under the internal mask layer 7. The device 9 is of identical size or not to the size of the first film 5'. Their edges are aligned or offset.

[0455] For example, the blur in the diffusing state of the roof with the variable diffusion device 9 is at least 80%.

[0456] As shown in the detail view, the variable diffusion device 9 comprises:

[0457] - a first support 91 (polymer, thermoplastic such as PET, 125 pm for example) with a first electroconductive coating 92 (for example ITO) on the second side F2

[0458] - an electroactive layer 93, which is based on liquid crystals in a polymer matrix (for example PDLC in English),

[0459] - a second 9T support (polymer, thermoplastic PET of 125pm for example) with a second electroconductive coating 92' (for example ITO) 92' on the third face F3.

[0460] 43

[0461] REPLACEMENT SHEET (RULE 26) The electrically conductive coatings 92, 92' at the periphery are not covered by the electroactive layer 93 and current supply strips 90 are placed at this location for the electrical supply. In particular, the supports 91, 9T protrude on two opposite sides.

[0462] For the purpose of protecting the electroactive layer 93, a chemical protection means 94 (barrier to possible plasticizers in the PVB) can be provided, for example by PET polymer frames arranged ad hoc, in particular a Z-section frame (three portions 941, 942, 943) coupled to a rectangular section frame 944.

[0463] Alternatively, the device 9 is replaced by another electroactive device, for example electrochromic or a functional PET film (tinted, etc.).

[0464] The assembly formed by the three-layer, the frame 34, the prismatic films 8, 8' forms a lower block 10 in adhesive contact with an upper block comprising or even formed by the electroactive device 9, the other frame 35 (identical size or different from the frame 34 depending on the extent of the electroactive device 9) and the upper interlayer 33.

[0465] The lower block and upper block assembly is designated as the complete block which is in adhesive contact with the glasses 1, 2 (bare or custom coated).

[0466] An example of manufacturing an illuminable self-laminated roof according to the invention first involves providing a roll of multi-layer laminated functional laminate in strip form, with at least the laminated tri-layer formed by the first interlayer 31, the first film 5' with the optical insulating coating 5 (or alternatively a fluoropolymer film), the lower interlayer 32, a tri-layer preferably carrying the light extraction layer 6 in one or more diffusing patterns, for example disjointed.

[0467] Figures 1a and 1b describe the main steps of manufacturing the illuminated laminated roof 100 from such a roll of laminated laminate.

[0468] Figure 1a illustrates in top view the main stages of manufacturing the illuminated laminated roof 100 with various cutting operations and local joining.

[0469] The first step 201 illustrates in a roll-to-roll process:

[0470] - continuous drawing of the laminated strip using 1000 and 1000' guide rollers along an X axis (horizontal),

[0471] - preferably a total pre-cutting (continuous) by blades 190 (in particular controlled cutting: pressure, movement, speed etc.), straight cutting for simplicity, along the two free edges of the strip (or alternatively a single free edge), so that the strip pre-cut in line has a free edge formed from the free edges of the first interlayer 31, of the first film 5 coated with the optical insulating coating 5' (or alternatively a fluoropolymer film), of the lower interlayer 32 with preferably the light extraction layer 6 in one or more diffusing patterns - a rectilinear lateral cutting (along Y) of the winding roller 1001 in particular when the strip length reaches at most 300 or 200m to facilitate handling, maintain the winding quality.

[0472] When the (each) excess peripheral strip is wide, it is wound onto another separate roll.

[0473] It is possible to offset the blade in Y (perpendicular to X, in a horizontal plane) during the pull, for a complex cut, for example oblique, and preferably still rectilinear (rather than curved).

[0474] The second step 202 illustrates the following operations:

[0475] - unwinding of roll 1001, with drawing of the functional three-layer laminate in strip,

[0476] - lateral rectilinear cutting along Y by blade 192 (controlled) to a desired length (predetermined) of the functional three-layer laminate.

[0477] The third step 203 includes (on an assembly table):

[0478] - with a blade 193, a circumferential and partial cut of the three-layer 31, 5, 5', 32, which is a total cut over a thickness E' of the first coated film 5, and of the lower interlayer 32, called the cut layer, leaving a frame surface 3T protruding from the first interlayer 31 preferably of width W1 of at least 20mm (and preferably at most 200mm or 100mm), called the whole layer.

[0479] The fourth step 204 includes (on an assembly table):

[0480] - the formation of the interlayer frame of lamination 34 with a thickness Ec preferably of at least 0.3mm (and in standard PVB) to be more easily handled without folds, with a width Wc preferably of at least 20mm (and even less than or equal to W1), preferably from an interlayer, in sheet form, (rectangular or other shape compatible with the desired dimensions and shape), by cutting with a blade 194.

[0481] It is preferable to use an automatic cutting system itself composed of a mounting table, possibly a belt, the blade supported in an adjustable tool which is itself integral with a horizontal movement system (in XY, preferably horizontal plane) of the carriage type mounted on a bridge.

[0482] By combining the different movements, it is possible to make the blade follow any cutting path. For example, a blade moves along the X axis of a bar and the bar moves along the Y axis of the belt.

[0483] Preferably, to press the element to be cut, there is suction by means of holes in the belt.

[0484] Of course, we can have a duplication of means, that is to say another blade supported in an adjustable tool.

[0485] Steps 203 and 204 are concomitant or consecutive or at different times (storage of the intermediate frame, the pre-cut laminate, etc.). The fifth step 205 comprises the formation of the lower block 110 manipulated comprising the trilayer and, secured by local bonds of the trilayer, the intermediate frame 34 and the two prismatic reflective films 8, 8' along opposite edges, here longitudinal edges of the trilayer (of general quadrilateral shape similar to the general shape of the glasses 1, 2, longitudinal edges parallel or not and / or lateral edges parallel or not).

[0486] The local connections (adhesive contacts) are in particular spot welds 195, by (local) softening of interlayer material preferably PVB (of the frame 34 and / or of the three-layer). The joining is preferably by local heating and possibly also by pressure. This joining is preferred to bonding by adding adhesive (bead of glue or double-sided adhesive).

[0487] The temperature and pressure are adjusted according to the interlayer material and the tool, in particular heated fingers or soldering iron.

[0488] With a soldering iron the temperature can be 250°C, the welds are fast and deep (possible melting of the entire thickness of the interlayer material, PVB), without pressure necessary.

[0489] With heated fingers (melting all or part of the thickness of the interlayer material, PVB), the temperature can be around 100°C and pressure is applied.

[0490] The local connections, especially for heating fingers, are preferably 8 to 15 mm long and spaced 20 cm to 30 cm apart.

[0491] For the 34 / tri-layer interlayer frame bonding, the contact zones for the local connections can be centered a few mm from the border between the frame and the tri-layer (which is a junction or an “inter-edge” space of at most 1 mm - between their edges -) alternately on either side of the border.

[0492] Several local connections are made (distributed regularly or not) around the entire perimeter of the intermediate frame 34 / lower intermediate layer 32.

[0493] The 34 / three-layer interlayer frame bonding can be done in one operation for all local connections. You can choose a heating tool that allows you to perform the various point adhesive points in a single operation, for example using heating fingers.

[0494] For example, 10mm heating fingers are on the lower interlayer 32 (rear face) and the interlayer frame 34 (rear face), centered alternately at 5mm from the boundary and on the lower interlayer 32 and at 5mm from the boundary and on the frame. The centering of the local melting (of the heating fingers) is schematically represented by circles in Figure 1a.

[0495] There is melting between the intercalary frame 34 and the lower intercalary layer 32 and also between the frame and the first intercalary layer 31. The prismatic films 8, 8' are secured by local bonds with at least the first intercalary layer 31 and the intercalary frame 34, by (local) softening of the intercalary material, by local heating (with heating fingers etc.).

[0496] The sixth step 206 comprises an assembly step comprising:

[0497] - a placement (and centering) on ​​the second glass sheet 2 called the reference sheet of the complete block 120 (lower block 110 secured to the upper block 111 as detailed in sectional view later in figure 1b)

[0498] - possible local bonding of the complete block 120 / second sheet 2, by local heating as mentioned above (multiple welding points) of the interlayer material (adhesive contact)

[0499] - positioning of the first sheet 1, carrying the masking frame 7 on the complete block 120

[0500] - possible local bonding of the complete block 120 / first sheet 1, by local heating as mentioned above (multiple welding points), of the interlayer material (adhesive contact)

[0501] - the puff pastry.

[0502] The lamination preferably includes:

[0503] - a vacuum (to evacuate the air present between the two sheets of glass, by suction etc, “cold”, at room temperature) for a period ranging from 15 to 45 min,

[0504] - heating at a temperature ranging from 80°C to 120°C for a period ranging from 30 to 60 min (in the case of interlayer material based on plasticized PVB and even partly without plasticizer).

[0505] After lamination, the first film 5, the reflective prismatic films 8', 8 are protected, encapsulated by lamination interlayer material (here PVB) by creep (of the first interlayer sheet 31 etc).

[0506] In particular in a first configuration of management of the interlayer edges:

[0507] - the complete block 120 is sized and positioned so that the edges of the intermediate frame 34, of the entire layer 31, each have an overhang of between 5 and 20 mm relative to the edges of the glass sheets 1, 2, the edges of the other intermediate frame 35, of the third intermediate layer 33 each have an overhang of between 5 and 20 mm relative to the edges of the glass sheets 1, 2

[0508] - the process includes trimming the complete block 120 before degassing (i.e. cutting to be edge to edge with the glasses 1, 2)

[0509] - after autoclave, the process includes brushing (removal) of excess PVB from the edge of the roof.

[0510] In particular in a second configuration for managing the interlayer edges, the complete block 120 is sized and positioned so that the edges of the interlayer frame 34 and of the other frame 35 and of the interlayer layers 31, 33 have a withdrawal of 0 to 4 mm relative to the edges 10, 20 of the glass sheets 1, in which case, there is no need for 'trimming' or 'brushing'.

[0511] Figure 1b illustrates in sectional view the main stages of manufacturing the self-laminated roof 100 with various cutting operations and local joining.

[0512] The first step 101 (corresponding to step 203 already described in top view in figure 1a) is the circumferential and partial cutting leaving the frame surface 3T protruding and a cut part comprising the elements 32, 5, 5'.

[0513] The second stage 102 of placement includes:

[0514] - placement of the 8.8' prismatic reflective films on the 31' frame surface and along the longitudinal edges of the cut-out part of the three-layer, ensuring that the 8.8' prismatic reflective films are less than 4mm and better 1mm from the edge of the first film 5 (or even attached to the edge of the first film 5).

[0515] The reflective prismatic films are preferably of width equal to that of the frame surface 31' or better preferably set back at least 5mm from the edge of the layer 31 and / or the glasses 1, 2.

[0516] The third stage 103 of solidarity includes:

[0517] - local bonding 195 of the prismatic reflective films 8.8' to the frame surface 31' (for example two welding points, by local softening of the frame surface (local heating, by heating fingers, as mentioned above, etc.).

[0518] The fourth step 104 of forming the lower block 110 (corresponding to step 205 in top view in FIG. 1a, described here in more detail) comprises in this order:

[0519] - placement of the intermediate frame 34 on the frame surface 31'

[0520] - a local joining 195 of the intermediate frame 34 to the frame surface 31', for example in multiple points, by local softening of the intermediate frame 34 and the frame surface 3T (local heating, by heating fingers, as mentioned above, etc.), in particular the intermediate frame 34 is edge to edge with the first intermediate layer 31 (or with an overhang or withdrawal of at most 1 mm) and spaced at most 1 mm or against the cut part of the three-layer; for example, a multi-point weld is made in one operation.

[0521] In the first variant, the formation of the lower block 110 comprises in this order:

[0522] - placement of the 8.8' prismatic reflective films (less than 4mm and better 1mm from the edge of the first film 5 or even attached) then following the intermediate frame 34 on the frame surface 31'

[0523] - and a single operation of local joining of the reflective prismatic films and the intermediate frame 34 with the three-layer, by local softening (local heating, by heating fingers as mentioned above, etc.), for example multi-point welding in one operation.

[0524] In the second variant, the formation of the lower block 110 comprises in this order: - a placement of the prismatic reflective films 8, 8' on the intermediate frame 34 (less than 4 mm and better 1 mm from the edge of the first film 5 or even attached),

[0525] - local pre-bonding of the 8.8' prismatic reflective films on the intermediate frame 34 (front face of the intermediate frame 34) by local softening of the frame (local heating, by heating fingers as mentioned above, etc.),

[0526] - placement of the intermediate frame 34 secured to the prismatic reflective films 8.8' on the frame surface 3T,

[0527] - local bonding of the reflective prismatic films linked to the intermediate frame 34 with the three-layer by local softening (local heating, by heating fingers, etc.), for example multi-point welding in one operation.

[0528] A step 104' (parallel, independent of the fourth step 104) of forming the upper block 111 with electroactive system 9 (here with liquid crystals) comprises:

[0529] - placement of the other intermediate frame 35 on the upper intermediate layer 33,

[0530] - if peripheral protection is necessary: ​​placement of the first Z-shaped protection frame 94 (in three sections 941, 942 and 943) on the internal periphery of the other intermediate frame 35, and joining of the first Z-shaped protection frame 941, 942, 943 with the other intermediate frame 35 by local softening of the other intermediate frame 35 (local heating, by heating fingers, etc.), for example multi-point welding (around the entire periphery) in one operation

[0531] - a placement of the electroactive element 9 for example based on liquid crystals (PDLC etc) within the other intermediate frame 35

[0532] - if peripheral protection is necessary: ​​placement of the second protective frame 944 (of rectangular section) on the other intermediate frame 35 (and on the periphery of the electroactive element 9), joining of the second protective frame 944 with the other intermediate frame 35 by local softening of the other intermediate frame 35 (local heating, by heating fingers etc.), for example multi-point welding (all around) in one operation. It is also possible to have a protected or robust electroactive element 9, in particular with already peripheral protection, for example a protective frame (polymer, PET etc.) of C-section.

[0533] The shape of the protective frames (C, Z etc) can be done by folding etc. We can also use a protective material (by liquid deposit etc).

[0534] In another variant, the electroactive element 9 comprises an internal peripheral protection, possibly an internal polymer seal between the two electroconductive films 91, 9T (on the periphery of the element 93).

[0535] This step 104' can be carried out before, during, or in parallel with step 104.

[0536] As a variant of this step 104', the electroactive element 9 is placed on the third interlayer 33, called the upper layer (PVB sheet), before the other interlayer frame 35 - therefore the second protective frame 944 is placed, the element 9 before the Z-shaped protective frame 941, 942, 943 and the other interlayer frame 35

[0537] - or we place element 9 with already a peripheral protection (in C) then the other intermediate frame 35.

[0538] The fifth step 105 of forming the complete block 120 (ready for assembly) includes:

[0539] - a placement of the lower block 110 on the upper block 111 composed of the electroactive element 9 with the other intermediate frame 35 locally secured to the third intermediate layer 33 and comprising the protective frames all around (frame 94 of Z-section 941, 942 and 943 and frame of rectangular section 944), therefore front face of the first intermediate layer 31 on (rear face of) the electroactive element 9 and on the other intermediate frame 35,

[0540] - (not shown) local joining of the first interlayer 31 with the other interlayer frame 35 (local heating, with heating fingers, multi-point welding, as already mentioned above, etc.) to form the complete block 120 which is easy to position and handle.

[0541] If necessary, the upper block 111 alone is preferably moved in horizontal translation - with the free face of the element 9 towards the sky - because preferably the electroactive element 9 is not linked to the third intercalary layer 33 (in its central part, no local links).

[0542] Once the complete block 120 is completed, it can be turned over (rotated 180°), especially if the second sheet 2 is chosen as the reference sheet.

[0543] The sixth step 106 of assembly for lamination includes:

[0544] - a placement (with centering) on ​​the second glass sheet 2 called the reference sheet of the complete block 120 (with the lower block 110 secured to the upper block 111), lower block being placed in contact with the face F3 13

[0545] - possible local bonding of the lower block / second sheet 2, by softening of the interlayer material (local heating, multi-point welding, etc.)

[0546] - a positioning of the first sheet 1, carrying the masking frame 7 on the block assembly 120

[0547] - possible local bonding of the upper block or even the complete block / first sheet 1 (local heating, multi-point welding, etc.)

[0548] Then we make the puff pastry.

[0549] All steps 101 to 106 are in a clean atmosphere, particularly in a clean room.

[0550] Glass sheets 1, 2 are clean.

[0551] The complete block 120 may further comprise peripheral connections (extending the glass sheets 1, 2, and between the two glass sheets 1, 2) for example to electrically supply the electroactive element 9.

[0552] Figure 1' represents a schematic sectional view of an illuminable laminated glass roof 100' of a motor vehicle according to the invention in a variant of the first embodiment. It differs in that the reflector prisms 8, 8' are within the intermediate frame 34 with double PVB sheets, 341, 342 (still forming part of the lower block 110'). The electroactive element 9 is here more extensive than the first film 5'. The opposite is also possible.

[0553] The upper sheet 341 on the first interlayer 31 side may be opaque, the lower sheet 342 is clear. For example, each sheet 341, 342 has a thickness (identical or distinct) of at least 0.3 mm and is made of plasticized PVB (usual).

[0554] The manufacture of the complete block 120' is quite similar to that described for the complete block 120 of figure 1. Only the differences are detailed in relation to figure 1'a illustrating in sectional view the stages of manufacture of the illuminable laminated roof 100'.

[0555] After the first partial cutting step is as already described previously, the second step 102 comprises:

[0556] - a pre-bonding 195 of the reflector prisms 8, 8' with the two upper 341 and lower 342 PVB frame sheets (usual) by local softening of the intermediate frame 34 (local heating, with heating fingers for example, in particular on two contact zones, in one operation)

[0557] - placement of the multi-sheet frame 34 with the reflector prisms 8, 8' on the frame surface 31'.

[0558] This is followed by a third step 103 comprising the securing 195 of the multi-sheet frame 34 with reflector prisms 8.8' on the first interlayer 31, by local softening of the interlayer frame 34 and the first interlayer (local heating, in particular with heating fingers all around, in one operation etc.).

[0559] Alternatively, the prismatic film(s) 8, 8' are pre-bonded (by local heating) first with the upper PVB sheet 341 which is then bonded with the first interlayer 31 and then the lower PVB sheet 342 is bonded (by local heating) with the upper sheet 341.

[0560] Alternatively, the prismatic film(s) have prisms 82, 83 oriented towards the face F2. Alternatively, a possible overlayer (protective, etc.), transparent, is interposed between the optical isolating coating 5 and the extraction layer 6.

[0561] Alternatively, the reflecting prisms 82, 83 are glued via a transparent local glue on the face F3, the smooth face is under the frame 34 or under the lower interlayer 32.

[0562] Figure 2 represents a schematic sectional view of an illuminable laminated glass roof 200 of a motor vehicle according to the invention in a second embodiment.

[0563] It differs from the first mode 100 in that:

[0564] - the reflecting prisms 82, 83 of the reflecting prismatic films 8, 8' are oriented towards the face F2 12, within the lower block 210, with the smooth face against or stuck to the face f3 13 - possibly an overlayer 51 (protective etc.), transparent, is interposed between the optical isolating coating 5 and the extraction layer 6.

[0565] The manufacture of the lower block 210, the upper block 111, the complete block 220 (lower block 210 and upper block 111) is quite similar to that described in figure 1a, certain manufacturing steps are detailed in relation to figure 2a.

[0566] After the first step of circumferential cutting and partial cutting as already described, a second step 102, of placement, comprises:

[0567] - placement of the intermediate frame 34 on the frame surface 3T,

[0568] - placement of the reflective prismatic films 8, 8' (reflective prisms 82, 83 oriented towards the intermediate frame 34) on the rear face of the intermediate frame 34.

[0569] This is followed by a third stage 103 of solidarity comprising:

[0570] - a joining 195 of the intermediate frame 34 with the first intermediate layer 31 and even of the lower intermediate layer 32 by local softening of the intermediate material - intermediate frame 34; first intermediate layer 31, lower intermediate layer 32 - (local heating, with heating fingers for example, on multiple contact zones.) and a joining 195 of the reflector prisms with the intermediate frame 34, by local softening of the intermediate frame 34 (local heating, with heating fingers for example, on multiple contact zones).

[0571] Alternatively, the second step 102 comprises:

[0572] - placement of the intermediate frame 34 on the frame surface 3T,

[0573] - a connection 195 of the intermediate frame 34 with the first intermediate layer 31.

[0574] And a third step 103 includes:

[0575] - placement of the reflective prismatic films 8, 8' (prisms 82, 83 towards the intermediate frame 34) on the front face of the intermediate frame 34

[0576] - a joining 195 of the reflecting prisms with the intermediate frame 34, by local softening of the intermediate frame 34 (local heating, with heating fingers for example, on multiple contact zones) and of the first intermediate layer 31.

[0577] The next step of forming the complete block 220, not shown, is similar to the fifth step 105 already described. The next step of placing the block 220 for lamination, not shown, is like the sixth step 106 already described.

[0578] Figure 2' represents a schematic sectional view of an illuminable laminated glass roof 200 of a motor vehicle according to the invention in a variant of the second embodiment.

[0579] It differs from the roof of the second mode 200 in that:

[0580] - the films 8, 8' are transparent prismatic films (monolithic or with a base covered with a textured layer, for example resin, embossed, etc.) or any other light redirection element (macroprism, etc.), without a reflective layer, spaced apart or integral with the face F4 14 and even here glued (by an optical glue 6') on the face F4 14, therefore the films 8, 8' are external to the lower block 211, the prisms 82 have a free surface (oriented towards the passenger compartment) or covered by a transparent overlayer (protective, etc.), the films can be all or part opposite the first film 5' (preferably remaining under the masking layer 7)

[0581] - possibly the lower interlayer 32' is a PVB without plasticizer (or with less than 10% or 5% plasticizer) for example 30pm or 50pm thick - and carrying here on the rear face of the light extraction layer in one or more diffusing patterns 6 (or alternatively on the front face),

[0582] - possibly the absence of layer 17

[0583] Alternatively the light extraction layer is on the F3 or F4 side, for example diffusing resin or diffusing enamel.

[0584] An optical element (collimator, etc.) can be inserted between the diodes and the films and / or side-emitting diodes can be chosen.

[0585] The manufacture of the complete block 221 (upper block 111 on lower block 211) includes:

[0586] - the circumferential and partial cutting leaving the frame surface 31' protruding and a cut part 32.5.5',

[0587] - the placement of the intermediate frame 34 on the protruding 3T frame surface, then local bonding, by softening of the intermediate material, of PVB (local heating, in particular by heating fingers),

[0588] - then the placement of the lower block 211 on the upper block 111, then local joining by softening of the interlayer material, of PVB (local heating, in particular by heating fingers) - as already described in the fifth step 105-.

[0589] The next step of placing the complete block 221 for lamination is for example identical to step 106 already described.

[0590] If E' is less than 200pm and better less than or equal to 150pm or even at most 100pm, the intermediate frame 34 can be removed. The protection is provided by creep of the PVB 31.

[0591] Alternatively, the upper block is removed.

[0592] We can add the already mentioned layer 17 and / or remove layer 18 and use a first tinted glass (and a tinted or clear upper interlayer 33).

[0593] The top block is optional.

[0594] Figure 3 represents a schematic sectional view of an illuminable laminated glass roof 300 of a motor vehicle according to the invention in a third embodiment.

[0595] The 300 roof differs from that of the second mode 200 in that:

[0596] - the optical isolator layer is formed by a 5” fluoropolymer film (corona treated) with a thickness of, for example, 50 pm, - possibly the lower interlayer 32' is a PVB without plasticizer (or with less than 10% or 5% plasticizer) for example 30 pm or 50 pm thick - and carrying here on the rear face of the light extraction layer in one or more diffusing patterns 6 (or alternatively on the front face),

[0597] - by the absence of an intercalary frame around the trilayer because E' is less than 200pm and even at most 150pm or 100pm.

[0598] The manufacture of the lower block 310 is partly described in Figure 3a:

[0599] - the first step 101 is the circumferential and partial cutting of the three-layer, total cutting of the 5” fluoropolymer film and the lower interlayer 32', PVB, leaving the 3T frame surface protruding and a cut part 32', 5”,

[0600] - the second step 102 is the placement of the reflector prisms 8, 8' (prisms 82, 83 towards surface 31') on the protruding frame surface 31', (reflector prisms 8, 8' less than 4mm and better 1mm from the edge of the 5” fluoropolymer film or even attached)

[0601] - the third step 103 is the local joining 195 of the reflecting prisms 8, 8', by softening of the interlayer material, PVB (local heating, by heating fingers), here of the first interlayer layer 31 and even of the lower interlayer layer 32'

[0602] The next step (not shown) of forming the complete block 320 (ready for assembly) involves:

[0603] - a placement of the lower block 310 on the upper block 111 already described, therefore front face of the first intermediate layer 31 on electroactive element 9 and on the other intermediate frame 35

[0604] - local joining of the first interlayer 31 with the other interlayer frame 35 (local heating, with heating fingers, multi-point welding).

[0605] The next step of placing the complete block 320 for lamination is for example identical to step 106 already described.

[0606] Figure 3' represents a schematic sectional view of an illuminable laminated glass roof 300' of a motor vehicle according to the invention in a variant of the third embodiment.

[0607] It differs from the roof of the third mode 300:

[0608] - in that the optical isolating layer is formed by the first PET film 5' for example with a thickness of 100 pm and the optical isolating coating 5 (for example as in the first mode 100),

[0609] - due to the absence of the upper block, the first interlayer 31 is in contact with the solar control layer 18 (if any) and the masking frame 7

[0610] - possibly a single prismatic reflective film 8 (and a single diode strip 4) for example on a longitudinal edge or on a lateral edge (front or rear). The manufacturing steps of the block 311 are identical to those described for the lower block 310 of figure 3.

[0611] The next assembly step for lamination involves:

[0612] - a placement (centering) on ​​the second glass sheet 2 called the reference sheet of the block 311, brought into contact with the face F3 13

[0613] - possible local bonding of the first interlayer 31 with the second sheet 2, by softening of the first interlayer (local heating, multiple welding points)

[0614] - a positioning (centering) of the first sheet 1, carrying the masking frame 7 and the layer 18 (if any) on the block 311

[0615] - possible local bonding of the first interlayer 31 with the first sheet 1 (local heating, multiple welding points).

[0616] Then we make the puff pastry.

[0617] Alternatively, the electroactive element is added, for example laminated by calendering, for example an all-solid electrochrome, preferably with a thickness of <200 pm and even at most 150 pm, without the need for another interlayer frame 35 so that the laminated laminate also comprises, in addition to the three-layer (and before the partial cutting of the laminate 101)

[0618] - the third interlayer 33

[0619] - the electroactive element, set back from the edges of the third interlayer 33 and the first interlayer 31, encapsulated, protected by these sheets.

[0620] Figure 4 represents a schematic sectional view of an illuminable laminated glass roof 400 of a motor vehicle according to the invention in a fourth embodiment.

[0621] It differs from the roof of the first mode 100 in that:

[0622] - the reflecting prisms 82, 83 of the prismatic films 8, 8' are oriented towards the face F2 12 and linked to the rear face of the lower interlayer 32, at the edge, always under the masking frame 7, and against or stuck to the face F3 13

[0623] - two opaque bands 7' (coating, black for example, on the first film preferably on the back face) are opposite the prismatic films 8, 8' in the event of stray light (crossing the prismatic films 8, 8')

[0624] - the electroactive element is replaced by a film with a solar control function, here a polymer film (polyester, for example PET, for example with a thickness of 50 pm to 200 pm) 9' carrying the electroconductive solar control coating 18 on the front face (the film can be tinted) or back face (preferably clear film), the third interlayer 33 (upper) being clear, the lower layer 32 also being clear, the first layer 31 also clear or tinted and one of the two layers 33, 31 or these two layers 33, 31 encapsulate the edges 90' of the film 9' with a solar control function. The electroconductive coating thus offset from the bare face F2 or which can have another functional coating). It is also possible to have a composite functional film without an electroconductive coating.

[0625] The laminate 420 is a laminated multilayer which comprises, in addition to the three-layer 32, 5' (with its coating 5), 31, - and the interlayer frame 34 on the periphery of the three-layer - the solar control film 9' (with its coating 18) and the third interlayer 33 (upper). And if necessary the multilayer laminate comprises two opaque strips 7' (coating, black for example, on the first film preferably on the rear face) opposite the prismatic films 8, 8' in the event of stray light (passing through the films 8, 8').

[0626] Alternatively, the edges 90' are aligned with the edge of the three-layer and even the interposed frame 34 (thicker) extends to the face F2 12. For example, a total cut of the multi-layer has been made with the frame 34 around the perimeter.

[0627] Concerning the manufacture of the roof 400 illustrated in part in figure 4a, the first step 101 of partial cutting 193 of the laminate to a thickness E', is as already described previously (the multilayer is just thicker).

[0628] This is followed by a second step 102 comprising:

[0629] -the placement of the reflective prismatic films 8,8' (prisms 82,83 towards the rear face), on the rear face of the lower interlayer 32, (opposite the opaque strips 7') This is followed by a third step 103 comprising:

[0630] - a joining 195 of the reflecting prismatic films 8, 8' by local softening of the lower interlayer 32 (local heating, with heating fingers for example on two contact zones, in one operation)

[0631] - placement of the intermediate frame 34 on the frame surface 31',

[0632] - a joining of the intermediate frame 34 by local softening of the lower intermediate layer 32 and the intermediate frame 34 (local heating, with heating fingers for example all around in one operation).

[0633] The order of the steps can be modified: placement of the intermediate frame 34 and its local fastening, placement of the prismatic reflective films 8.8' and their local fastening.

[0634] It is also possible to place the intermediate frame 34 and the prismatic reflective films 8, 8' and to make a connection between the intermediate frame 34 and the prismatic reflective films 8, 8' in a local heating operation.

[0635] Figure 5 represents a schematic sectional view of an illuminable laminated glass roof 500 of a motor vehicle according to the invention in a fifth embodiment.

[0636] It differs from the roof of the first mode 100 in that:

[0637] - the lower interlayer 32 is whole - the first interlayer 31 is shorter than the lower interlayer 32 (set back from the layer 31)

[0638] Thus, the first interlayer 31 is a cut layer leaving a frame surface 321 protruding from the lower interlayer 32 in particular with a width W1 of at least 20 mm and for example at most 100 mm or 50 mm.

[0639] The interlayer frame 34 is on the periphery of the first interlayer layer 31 (and of the first film 5 with its coating 5' or of a fluoropolymer as a variant).

[0640] The reflector prism films 8, 8' are between the rear face of the intermediate frame 34 and the front face of the lower intermediate layer 32 or alternatively between the front face of the upper intermediate layer 32 and the face F3 13, reflector prisms glued via a local glue, opposite the first film or spaced at most 4 mm or even 1 mm from the edge of the film 5.

[0641] The manufacture of the lower block 510, of the complete block 520 is described in relation to figure 5a.

[0642] The first step 101 is the circumferential and partial cutting of the three-layer by blade 193 leaving the frame surface 321 protruding and a cut part 31,5,5' of the three-layer.

[0643] The second stage 102 of placement includes:

[0644] - placement of the reflective prismatic films 8, 8' on the frame surface 321 and along the longitudinal edges of the cut part of the three-layer. less than 4 mm and better 1 mm from the edge of the first film 5 or even attached).

[0645] The third stage 103 of solidarity includes:

[0646] - local bonding 195 of the reflective prismatic films 8.8' to the frame surface 321 (by local softening of the frame surface 321, by local heating, for example two welding points,)

[0647] - the placement of the intermediate frame 34 on the prismatic reflective films 8.8' and the frame surface 321.

[0648] The fourth stage 104 of solidarity includes:

[0649] - local bonding 195 of the intermediate frame 34 to the frame surface 321 by local softening of the frame surface 320 (for example all around, by local heating, by multiple welding points, by heating fingers).

[0650] The fifth step 105 of forming the complete block 520 includes:

[0651] - the successive placement of the protective film 944, of the electroactive element 9, of the protective film 94, of the other intermediate frame 35, of the third intermediate layer 33 (upper)

[0652] - local joining of the assembly 944, 94, 35 by local softening of the interlayer material of the other interlayer frame 35, of the interlayer frame 34, of the third interlayer layer 33.

[0653] It is possible to alternatively place and secure the protective film 944, place the electroactive element 9, place the protective film in Z 94, place the other intermediate frame 35 and secure it with the intermediate frame 34 and protective films 94 and 944, place the third intermediate layer 33 and secure it with the other intermediate frame 35.

[0654] If we prefer to place the other frame 35 before the electroactive element 9, then we place in this order protective film 94, other frame 35, electroactive element 9, protective film 944.

[0655] The next step of placing the complete block 520 for the lamination 106 is for example identical to step 106 already described previously.

[0656] In another configuration (see figure 5b) the fifth step 105 of forming the complete block 520 (ready for assembly) comprises:

[0657] - placement of the lower block 510 on the upper block 111 (front face of the intermediate frame 34 and of the first intermediate layer 31 on the rear face of the element 9 and the other intermediate frame 35, -and also on the protective film 94)

[0658] - (not shown) a local connection of the intermediate frame 34 with the other intermediate frame 35. (local heating, with heating fingers, multi-point welding)

[0659] Alternatively, the lower block 510' comprises:

[0660] - a 5” fluoropolymer film (corona treated) instead of the first 5' film with the low index 5 coating

[0661] - and / or for the lower interlayer 32', a PVB with little or no plasticizer; thin; carrying on its rear face the diffusing pattern(s) 6

[0662] - and / or one or more reflecting prisms 8, 8' in a multi-sheet frame 341, 342 for example on two opposite edges.

[0663] The upper sheet 341 on the first interlayer 31 side may be opaque, the lower sheet 342 is clear. For example, each sheet is at least 0.3 mm thick and made of plasticized PVB (usual).

[0664] As shown in Figure 5c, the formation of this lower block 510' comprises in this order (after partial cutting of the trilayer):

[0665] - a pre-solidarization 195 of the reflector prisms 8, 8' with two PVB frame sheets 341, 342 by local softening of the intermediate frame 34 (local heating, with heating fingers for example on two contact zones, in one operation)

[0666] - a second step 102 of placing the multi-sheet frame 34 with the reflector prisms 8, 8' on the frame surface 321,

[0667] - a third step 103 comprising the securing of the multi-sheet prism frame 34 to the lower interlayer 32' (entire), by local softening of the interlayer frame 34 and the lower interlayer 32' (local heating, with heating fingers, all around, in one operation). The fact of carrying out the partial cutting on the first interlayer 31 possibly makes it possible to use a single thick interlayer frame 34' (mono or mu Itifeu i I let) to protect both the electroactive element 9 and the optical isolator layer 5 having similar dimensions and therefore to reduce the operations.

[0668] As shown in Figure 5d, the fifth step 105 of forming the complete block 520 then comprises:

[0669] - successive placement:

[0670] - the thick frame 34' on the surface 321 (with the prismatic films 8.8' possibly already), - the protective film 94 in Z on the first interlayer 31

[0671] -of the electroactive element 9 out of 94 and on the first intercalary layer 31

[0672] - protective film 944 on element 9 and on 94 and 34' spacer frame

[0673] - of the third intercalary layer 33 (wider than element 9)

[0674] - local bonding of the assembly by local softening of the interlayer material (local heating), of the interlayer frame 34', of the lower interlayer layer 32, of the third interlayer layer 33.

[0675] Alternatively, one can place and secure the interlayer frame 34' with the lower interlayer layer 32, place the protective film in Z 94, place element 9, and secure it with the interlayer frame 34 and films 94 and 944, place the third interlayer layer 33 and secure it with the interlayer frame 34' (local heating).

[0676] Alternatively, it is possible to place and secure the interlayer frame 34' already carrying the prismatic films (on the surface or in a multi-layer) with the lower interlayer layer 32, place the protective film in Z 94, place element 9, secure the films 94 and 944 with the interlayer frame 34, place the third interlayer layer 33 and secure with the interlayer frame 34'.

[0677] The electroactive element 9 can already be protected, for example, by a PET frame film with a C-section instead of 94 and 944. Optionally, the lower interlayer is a PVB without plasticizer, for example 30 pm, carrying the diffusing coating on the rear (or front) face.

[0678] As shown in Figure 5e, the fifth step 105 of forming the complete block 520 then comprises:

[0679] - successive placement:

[0680] - 8.8' prismatic reflective films on the frame surface 321, prismatic reflective films of width equal to that of the frame surface or even set back preferably by at least 5mm, ensuring that the 8.8' prismatic reflective films are less than 4mm and better 1mm from the edge of the 5” film (or even attached to the edge of the 5” film)

[0681] -from the 34' thick frame, on the 8.8' prismatic reflective films and the 321 frame surface

[0682] - of the protected electroactive element 9,

[0683] -of the third interlayer 33 on the element 9 and the frame 34'

[0684] - local bonding of the assembly by local softening (local heating) of the interlayer material (of the interlayer frame 34', of the lower interlayer layer 32', of the third interlayer layer 33). It is possible alternatively to place and bond the interlayer frame 34' already carrying the prismatic films (on the surface or in a multi-layer) with 32, place element 9, place the third interlayer layer 33 and bond it with the interlayer frame 34'.

[0685] Figure 6 represents a schematic sectional view of an illuminable laminated glass roof 600 of a motor vehicle according to the invention in a sixth embodiment.

[0686] It differs from the roof of the first mode 100:

[0687] -in that within the lower block 210, the reflecting prisms 82, 83 of the films 8, 8' are oriented towards the face F2 12, smooth face against face F3 13, textured face against rear face of the lower interlayer 32 (preferably plasticized PVB, at least 0.3mm)

[0688] - by the absence of an intercalary frame around the edge of the optical isolator layer (first film 5' and coating 5 or fluoropolymer film as a variant), in particular Ep <200pm or at most 150pm or even 100pm for example 75pm.

[0689] The manufacture of the lower block 610 is described in part in relation to Figure 6a:

[0690] - first step 101: possible: marginal cutting of the interlayers 31, 32 (to the size of the glasses 1, 2 and even according to the shape of the glasses), the optical isolator layer being intact

[0691] - second step 102: placement of the prismatic films 8, 8' on the rear face of the lower interlayer 32

[0692] - third step 103: joining 195 of the prismatic films 8, 8' with the lower interlayer 32 (by local heating).

[0693] This results in the formation of the complete block 620 (not shown):

[0694] - placement of the lower block 610 (turned over, by rotation 180°) on the upper block 111 as already described,

[0695] - (not shown) joining by local heating of the blocks by softening of the first interlayer 31 and of the other interlayer frame 35, of the lower interlayer 32. The following assembly step for lamination comprises:

[0696] - a placement (centering) on ​​the second glass sheet 2 called the reference sheet of the complete block 620

[0697] - possible local joining of the complete block / second sheet 2, by softening (local heating) of the first interlayer 31, of the other interlayer frame 35, of the lower interlayer 32 (multiple welding points)

[0698] - positioning of the first sheet 1, carrying the masking frame 7 on the complete block 620

[0699] - possible local bonding third interlayer 33 / first sheet 1 (local heating, multi-point welding) The lamination is then carried out.

[0700] Alternatively, the electroactive element 9 can be laminated by calendering, for example, an all-solid electrochrome, with a thickness of at most 200 μm, without the need for another intermediate frame 35 so that the laminated laminate also comprises, in addition to the three-layer (and before the possible marginal cutting),

[0701] Figure 7 represents a schematic sectional view of an illuminable laminated glass roof 700 of a motor vehicle according to the invention in a seventh embodiment.

[0702] It differs from the first mode 100 in that:

[0703] - the reflecting prisms 82, 83 of the films 8, 8' are oriented towards the face F2 12, within the lower block 210

[0704] - the sheets 31, 5, 32 are edge to edge so that the intermediate frame 34 (clear or tinted) is in contact with the other intermediate frame (clear or tinted) 35.

[0705] The electroactive element 9 is here the same size as the first interlayer 1. However, it can be larger or smaller indifferently.

[0706] Figures 7a to 7b describe the main steps in manufacturing the illuminated laminated roof 700.

[0707] Figure 7a illustrates in top view the main stages of manufacturing the illuminated laminated roof 100 with various cutting operations and local joining.

[0708] The third stage 203 includes:

[0709] - a circumferential and total cutting of the first interlayer 31, of the first film 5 and of the lower interlayer 32.

[0710] The fourth step 204 includes:

[0711] - the formation of the interlayer frame of lamination 34 with a thickness Ec preferably of at least 0.3mm to be more easily handled without folds etc., with a width Wc preferably of at least 20mm (and less than or equal to W1), preferably from an interlayer (rectangular sheet etc.) by cutting with a blade 194 (on a mounting table).

[0712] Steps 203 and 204 are concomitant or consecutive or at different times (storage of the frame, pre-cut laminate, etc.).

[0713] The fifth step 205 comprises the formation of the lower block 710 comprising the trilayer and, secured by local bonds to the trilayer, the intermediate frame 34 and the two prismatic reflective films 8,8' along opposite edges, here longitudinal edges, of the trilayer (quadrilateral). The two prismatic reflective films 8,8' are adjacent to the trilayer.

[0714] The bonds are in particular spot welds 195, by (local) softening of interlayer material (of the frame and / or the three-layer). The bonding is by local heating and possibly also by pressure. This bonding is preferred to gluing by bead of glue or double-sided adhesive.

[0715] The temperature and pressure are adjusted according to the interlayer material and the tool, in particular heated fingers or soldering iron, the temperature is around 100°C and pressure is applied.

[0716] For the 34 / tri-layer interlayer frame bonding, the contact zones for the local bonds can be centered a few mm from the boundary between the 34 and tri-layer interlayer frame (which is a junction or interlayer space of at most 1 mm) and on either side of the boundary.

[0717] Several local connections are made around the entire perimeter of the intermediate frame 34 / lower intermediate layer 32.

[0718] The 34 / three-layer interlayer frame bonding can be done in one operation for all local connections. You can choose a heating tool that allows you to perform the various point adhesive points in a single operation, for example using heating fingers.

[0719] For example, 10mm heating fingers are on the lower interlayer 32 (rear face) and the interlayer frame 34 (rear face), centered alternately at 5mm from the boundary and on the lower interlayer 32 and at 5mm from the boundary and on the frame. The centering of the heating fingers is represented by circles in Figure 7a.

[0720] Similarly, the prismatic films are secured by local bonds with the intercalary frame 34, by (local) softening of the intercalary material, by local heating (with heating fingers, etc.).

[0721] The sixth step 206 comprises an assembly step comprising:

[0722] - a placement on the second glass sheet 2 called the reference sheet of the complete block 720 (lower block 110 secured to the upper block 111 as detailed in sectional view later in figure 7b)

[0723] - possible local bonding (local heating) lower interlayer 32 / second sheet 2

[0724] - positioning of the first sheet 1, carrying the masking frame 7 on the complete block 120

[0725] - possible local bonding (local heating), third interlayer 33 / first sheet 1.

[0726] The lamination then includes:

[0727] - a vacuum (to evacuate the air present between the two sheets of glass, by suction etc., cold, room temperature) for a period ranging from 15 to 45 minutes,

[0728] - heating at a temperature ranging from 80°C to 120°C for a duration ranging from 30 to 60 min (in the case of interlayer material based on plasticized PVB and even partly without plasticizer). After lamination, the first film 5, the reflective prismatic films 8', 8 are protected, encapsulated by lamination interlayer material (PVB here).

[0729] Figure 7b illustrates in sectional view the main stages of manufacturing the self-laminated roof 700 with various cutting operations and local joining.

[0730] The first step 101 is a total cutting of the laminate 31, 5, 5', 32 preferably by a blade 193.

[0731] The second step 102 includes:

[0732] - placement of the intermediate frame 34 on the electroactive element 9 (with protective films 94,944) and on the other frame 35 of the upper block 111

[0733] - placement of the 8.8' prismatic reflective films on the intermediate frame 34 close to the inner edge of the intermediate frame 34 (to be less than 4mm and better 1mm from the edge of the first film 5 or even attached)

[0734] - local pre-bonding of the 8.8' prismatic reflective films on the frame 34 (rear face of the intermediate frame 34) by local softening of the frame (local heating, by heating fingers, etc.),

[0735] - the placement of the cut three-layer in frame 34 (and possible local bonding (local heating) of the cut three-layer / frame 34.

[0736] An alternative way of manufacturing the roof 700 is shown in Figure 7c, particularly if the lower block is removed.

[0737] The first step 101 remains a total cutting of the laminate preferably by a blade 193.

[0738] The second step 102 includes:

[0739] - placement of the 8.8' reflective prismatic films on the F3 face of the second glass sheet 2, prisms oriented opposite the F3 face

[0740] - placement of the intermediate frame 34 on the 8.8' prismatic reflective films close to the inner edge of the frame 34 (to be less than 4mm and better 1mm from the edge of the first film 5 or even attached)

[0741] - local pre-bonding of the reflective prismatic films 8, 8' on the frame 34 (rear face of the intermediate frame 34) by local softening of the frame (local heating, by heating fingers etc.),

[0742] - placement of the cut three-layer in frame 34

[0743] - local bonding of the three-layer with frame 34 (local heating, by heating fingers, etc.),

[0744] This is followed by the placement of the first sheet of glass 1 and then the lamination.

[0745] An alternative for manufacturing the roof 700 is presented in figure 7d in particular if the upper block is removed. - on the face F2 of the first sheet 1, placement of the frame 34 then of the three-layer cut within the frame 34, local bonding

[0746] - placement of the prismatic reflective films 8, 8' on the intermediate frame 34 close to the inner edge of the frame 34 (to be less than 4mm and better 1mm from the edge of the first film 5 or even attached)

[0747] - local bonding of the reflective prismatic films 8, 8' to the frame (front face of the intermediate frame 34) by local softening of the frame (local heating, by heating fingers, etc.),

[0748] This is followed by the placement of the second sheet of glass 2 and then the lamination.

[0749] Or we can also plan:

[0750] - on face F2 of the first sheet 1, placement of the frame 34 with the 8.8' prismatic reflective films pre-bonded (by local heating, by heating fingers, etc.) then of the three-layer cut within the frame 34, and local bonding.

[0751] This is followed by the placement of the second sheet of glass 2 and then the lamination.

[0752] An alternative way of manufacturing the roof 700 is shown in Figure 7e, particularly if the lower block is removed.

[0753] - on the face F2 of the first sheet 1, placement of the multi-sheet frame 34 341, 342 housing the pre-bonded 8,8' prismatic reflective films then of the three-layer cut within the frame 34, local bonding.

[0754] This is followed by the placement of the second sheet of glass 2 and then the lamination.

[0755] An alternative manufacturing method for the roof 700 is shown in Figure 7f in which there is a common interlayer frame 34' (PVB) for the laminate and the electroactive element 9.

[0756] A step 102 (after complete cutting of the three-layer) is the placement on the rear face of the lower interlayer 32 of the reflective prismatic films 8, 8' and their joining by local connections (local heating).

[0757] A next step 103 is on the third interlayer sheet 33 the placement of the common frame 34' thick, then in the common frame 34' placement of the electroactive element 9' already protected by e.g. C film 94, of the three-layer laminate with the reflective prismatic films 8, 8'.

[0758] Figure 7' represents a schematic sectional view of an illuminable laminated glass roof 700 of a motor vehicle according to the invention in a variant of the seventh embodiment.

[0759] It differs from mode 700 in that the reflector prisms 82, 83 of the films 8, 8' are on the back side of the lower interlayer 32, the interlayer frame 34' is common for the laminate and the electroactive element 9. Optionally the solar control coating 18 is omitted and the glass 1 is a tinted glass.

[0760] The manufacture of the complete block 720' is quite similar to that described for the complete block 720 of figure 1. It is preferred that the prismatic films are not in the laminate laminated by calendering but added after calendering, because there is a risk of damaging them.

[0761] Figure 8 shows a schematic view of a method of forming the functional laminate roll in strip 212 in a first configuration, roll-to-roll method, with in figures 8' and 8” laminate variants according to the invention which can be obtained by this method.

[0762] The method of forming the functional laminate roll 1001 comprises:

[0763] - from the unwinding of a roll called first interlayer unwinding roll 2002 comprising the first interlayer layer (sheet) 31 in a strip, preferably which is based on thermoplastic material such as PVB (clear or tinted) with preferably at least 20% plasticizer, with a thickness of at least 0.3 mm, possibly multi-sheet (acoustic PVB), a first continuous draw of the first interlayer layer (sheet) 31, in a strip, having main faces for example of roughness defined by a parameter Rz of at least 50 pm, and with preferably three guide rollers 2012, 2022, 2032,

[0764] - from the unwinding of a composite roll 2001, comprising a bilayer (laminated) comprising the optical insulating layer with said first film 5, thermoplastic coated with an optical insulating coating 5' (optionally with protective overcoat) bonded (pre-laminated, in adhesive contact with) with the lower interlayer 32' (clear) which is based on thermoplastic material such as PVB with preferably at most 5% or 1% or 0% of plasticizer, preferably with a thickness Ei of at most 80pm and even at most 50pm or 35pm, having a main face for bonding with the first film 5' and the coating 5 and a face opposite the bonding face, the light extraction layer (coating with diffusing patterns) being here on the opposite face (free face at this stage) smooth with roughness Rz defined by a parameter of at most 50pm, a second continuous drawing of the bilayer, in strip, with preferably a 2011 guide roller

[0765] - heating of the first interlayer 31 in strip, by means of IR resistors 1111 close to the strip

[0766] - near the heating, the formation of the laminated laminate by calendering 2111 in this order of the first heated interlayer 31, of the bilayer with the diffusing patterns 6 in contact with a calendering roller in particular made of rubber

[0767] - possibly after calendering one or more guide rollers 1000 and even cooling

[0768] - if necessary the insertion of a temporary protective polymer film 36 (non-stick) for example polyethylene (PE) -, strip unrolled from a roll 1011 (of PE) - before winding so that the free face of the outermost interlayers of the laminate (here first interlayer 31, lower interlayer 32',) are not in contact with each other, are separated by the temporary protective film, - the winding of the laminated laminate on the so-called winding roller 1001.

[0769] A total cut along the edges of the strip laminate 212 and / or a lateral cut 190 may occur.

[0770] To make the unwinding more reliable, you can use inflatable mandrels.

[0771] The rollers of the calender can be metallic, polymer (rubber) or one metal, the other polymer (rubber).

[0772] The rear face of the first interlayer 31 intended to be in adhesive contact with the first film 5' (carrying the coating 5) after lamination is preferably smooth. The front face may be smooth or rough, particularly if in adhesive contact with the face F2.

[0773] The back face of the lower interlayer 32' coated with the diffusing coating is smooth. The diffusing coating 6 may be a hard coat with sufficient hardness (at least 1 H) to be in contact with the calender. The diffusing coating 6 in one or more diffusing patterns 6 is preferably with a coverage rate of at most 30%.

[0774] The bilayer first coated film 5', 5 / lower interlayer 32' can be obtained from two sheets (first coated film 5', 5 and PVB sheet 32') or by liquid deposition of a PVB-based resin on the first film 5' (on the optical isolator coating 5 preferably on the back face rather than the front face). Then the diffusing coating is produced by liquid means, for example by printing (inkjet, roller, etc.).

[0775] We can also do variations:

[0776] - a strip laminate with the diffusing coating 6 between the optical isolating coating 5 (possibly protected) and the rear face of the lower interlayer 32 (preferably diffusing coating by liquid deposition (inkjet printing, roller) on the rear face or on the optical isolating coating 5 (possibly protected)

[0777] - a strip laminate 213 (see figure 8') with the diffusing coating between a first film which is 5” fluoropolymer, in particular corona treated (for example FEP of 50pm), from the roll 2001, and the rear face of the lower interlayer 32' (preferably diffusing coating by liquid deposition on the front face of the layer 32' or alternatively on the rear face)

[0778] - a strip laminate 214 (see figure 8”) with the diffusing coating 6 between the optical isolating coating 5 (possibly protected) and the rear face of the lower interlayer 32' which is preferably made of conventional plasticized PVB with a thickness of at least 0.3 mm, in particular with at least 10% or 15% of plasticizers and even at most 30% or 20%, preferably a diffusing coating by liquid deposition (printing, inkjet roller) on the optical isolating coating 5. Figure 9a represents a schematic view of a method for forming a roll used for manufacturing the functional laminate, in a first configuration, a roll-to-roll method.

[0779] This process includes:

[0780] - from the unwinding of a primitive roll 3001 comprising the first thermoplastic film 5' (PET) and the optical insulating coating 5 in strip, a primitive print of said first coated thermoplastic film 5', 5 in strip, preferably with a guide roll 3011

[0781] - the liquid deposition here for example by printing via ink roller 3002 on the optical insulating coating 5 of a so-called extracting composition comprising a transparent (organic) matrix and diffusing particles, in one or more patterns, to form the light extraction layer, during said original printing

[0782] - a winding of the first film with the optical isolating coating and the light extraction layer 6 in a winding roller 2001.

[0783] The roll can be unrolled as is for the second print (used in a mode related to the following figure 10) we add the lower interlayer 32 (used in a mode related to the previous figure 8” for example) for example PVB with a thickness of at least 0.3mm and with at least 10% or 15% and even at most 30% or 20% of plasticizers.

[0784] Alternatively:

[0785] - from the unwinding of a primitive roll 3001 comprising the first thermoplastic film 5 in strip, a primitive drawing of said first thermoplastic film in strip, preferably with a guide roll 3011

[0786] - the liquid deposition of a composition called an insulating composition to form the optical insulating coating, during said initial drawing,

[0787] - liquid deposition, here for example by printing via ink roller 3002 on the optical insulating coating of a so-called extracting composition comprising a matrix and diffusing particles, forming several patterns in one, to form the light extraction layer, in particular during said initial printing or in resumption during a following printing

[0788] - possible winding of the first film with the optical isolating coating and the light extraction layer in a winding roll, unwinding roll for the second print.

[0789] Figure 9b shows a schematic view of a method of forming a roll used for manufacturing the functional laminate, in a second configuration, a roll-to-roll method.

[0790] It differs from the previous method in that the deposition of the so-called extracting composition is by ink jet 3012. Figure 10 represents a schematic view of a method of forming the functional laminate roll in a second configuration, roll-to-roll method.

[0791] The method of forming the functional laminate roll 1001' comprises:

[0792] - from the unwinding of a roll called first interlayer unwinding roll 2002 comprising the first interlayer layer (sheet) 31 in strip, preferably which is based on thermoplastic material such as PVB (clear or tinted) with preferably at least 20% plasticizer, preferably with a thickness of at least 0.3 mm, possibly multi-sheet (acoustic PVB), a first continuous draw of the first interlayer layer (sheet), in strip, having main faces for example of roughness defined by a parameter Rz of at least 50 pm, and with preferably three guide rollers 2012, 2022, 2032,

[0793] - from the unwinding of a roll called 200T insulator roll, comprising the optical insulator layer 5, the first thermoplastic film 5' here carries on the rear face (which will be oriented towards the face F2) the optical insulator coating 5 and the light extraction layer 6 (coating with diffusing patterns) which is on the optical insulator coating (directly or via a protective layer (not shown), a second continuous drawing of the optical insulator layer with the light extraction layer, in strip, preferably with a guide roller 2011

[0794] - from the unwinding of a roll called the lower interlayer unwinding roll 2003 comprising the lower interlayer layer 32 preferably which is based on PVB (in sheet) plasticized with at least 10% and for example at most 30% or 20% of plasticizer and preferably with a thickness Ei of at least 0.3 mm, a third continuous print run separate from the first and second print runs, having for example a smooth rear main face with a roughness defined by a parameter Rz of at most 50 pm, print run preferably with guide rollers 2013, 2023, 2033

[0795] - heating of the first interlayer 31 in strip, by means of IR resistors 1111 close to the strip

[0796] - possibly heating of the lower interlayer 32 in strip, by means of IR resistors 1112 close to the strip

[0797] - near the heaters, the formation of the laminated laminate by calendering in this order of the first heated interlayer 31, the first film 5' (with coatings 5, 6), the lower heated interlayer 32, with the diffusing patterns in contact with a calendering roller, in particular made of rubber

[0798] - after calendering, possibly one or more 1000 guide rollers and even cooling rollers

[0799] - if necessary the insertion of a temporary protective polymer film 36 (non-stick) for example polyethylene, (PE)-, strip unrolled from a roll 1011 (of PE)- before winding so that the free face of the outermost interlayers of the laminate (here first interlayer 31, lower interlayer 32) are not in contact with each other, are separated by the temporary protective film.,

[0800] -- winding of the laminated laminate 215 onto the so-called 100T winding roller.

[0801] A total cut along the edges of the strip laminate 215 and / or a lateral cut 190 may take place.

[0802] The diffusing coating may be a hard coating with sufficient hardness (at least 1 H) to be in contact with the calender. The diffusing coating in one or more diffusing patterns 6 is preferably with a coverage rate of at most 30%.

[0803] Figure 11 shows a schematic view of a method of forming the functional laminate roll in a third configuration, roll-to-roll method with in figures 11' and 11” laminate variants that can be obtained.

[0804] The process of forming the 1001” functional laminate roll includes:

[0805] - from the unwinding of a roll called first interlayer unwinding roll 2002 comprising the first interlayer layer (sheet) 31 in strip, preferably which is based on thermoplastic material such as PVB (clear or tinted) with preferably at least 20% plasticizer, preferably with a thickness of at least 0.3 mm, possibly multi-sheet (acoustic PVB), a first continuous draw of the first interlayer layer (sheet), in strip, having main faces for example of roughness defined by a parameter Rz of at least 50 pm, and with preferably three guide rollers 2012, 2022, 2032,

[0806] - from the unwinding of a roll called isolator roll 2001”, comprising the optical isolator layer 5, the first thermoplastic film 5' is here carrying on the rear face (which will be oriented towards the face F3) the optical isolator coating 5 with a possible protective layer (not shown), a second continuous drawing of the optical isolator layer in strip, preferably with a guide roll 2011

[0807] - from the unwinding of a roll called lower interlayer unwinding roll 2003' comprising the lower interlayer layer 32 preferably which is based on thermoplastic material such as PVB with at most 5% or 1% or 0% of plasticizer, preferably with a thickness Ei of at most 80 pm and even at most 50 pm or 35 pm, having a main face for connection with the first coated film 5,5' and a face opposite the connection face, the light extraction layer 6 (coating with diffusing patterns) being here on a smooth face of roughness Rz defined by a parameter of at most 50 pm (here the connection face), a third continuous print run separate from the first and second print runs, print run preferably with guide rollers 2013, 2023, 2033

[0808] - heating of the first interlayer 31 in strip, by means of IR resistors 1111 close to the strip

[0809] 69

[0810] RECTIFIED SHEET (RULE 91) ISA / EP - a heating of the lower interlayer 32 in strip, by means of IR resistors 1111 close to the strip

[0811] - near the heaters, the formation of the laminated laminate by calendering in this order of the first heated interlayer 31, the first film 5 (with coatings 5, 6), the lower heated interlayer 32, with the diffusing patterns in contact with a calendering roller, in particular made of rubber

[0812] - possibly one or more 1000 guide rollers and even cooling rollers

[0813] - if necessary the insertion of a temporary protective polymer film 36 (non-stick) for example polyethylene, (PE)-, strip unrolled from a roll 1011 (of PE)- before winding so that the free face of the outermost interlayers of the laminate (here first interlayer 31, lower interlayer 32) are not in contact with each other, are separated by the temporary protective film.,

[0814] - the winding of the laminated laminate 216 onto the so-called winding roller 1001”.

[0815] A total cut along the edges of the strip lamination 215 and / or a lateral cut 190 may occur.

[0816] The diffusing coating 6 may be a hard coating with sufficient hardness (at least 1 H) to be in contact with the calender. The coating in one or more diffusing patterns 6 is preferably with a coverage rate of at most 30%.

[0817] We can also do as a variant:

[0818] - a strip laminate 217 (see figure 1 T) with the first film which is fluoropolymer 5” in particular corona treated (for example FEP in particular of 50pm) from the roll 2001”, with the diffusing coating 6 on the lower interlayer 32' (preferably diffusing coating by liquid deposition) for example here on the face opposite the bonding face,

[0819] - a strip laminate 218 (see figure 11”) with the diffusing coating 6 on the lower interlayer 32' (preferably diffusing coating by liquid deposition, for example here on the face opposite the bonding face), from the roll 2003'.

Claims

CLAIMS 1. Method for manufacturing an illuminated laminated glass roof for a vehicle, particularly a road vehicle (100 to 710), comprising a curved, transparent laminated glazing unit comprising: - a first sheet (1), transparent, made of mineral glass, with a first main face F1 (11), a second main face F2 opposite (12), intended to form the outer glass, - a transparent polymer lamination interlayer (3, 31, 32, 33), comprising a first thermoplastic interlayer (31); and a second thermoplastic interlayer (32), called the lower interlayer, - a second sheet (2), transparent, made of mineral or polymer glass, with a third main face F3 (13), a fourth main face F4 opposite (14), with a refractive index n1 in the visible - an optical isolator layer (5.5”), transparent, with a refractive index n2 in the visible such that n2 <n1 , - a light extraction layer (6) the lower interlayer extends between the first interlayer and the face F3, the light extraction layer being in contact with the lower interlayer and between the optical isolator layer (5) and the face F3 the method comprising in this order: - an assembly step comprising: - placing on one of the first and second sheets, called the reference sheet, the first interlayer and the lower interlayer - a positioning of the other of the first and second sheets, called the other sheet, - a lamination characterized in that the assembly step comprises the placement on the reference sheet of a functional laminate including a laminated trilayer comprising in this order: - the first interlayer (31), with a thickness E1 of at least 0.3 mm - said optical isolator layer which comprises or is supported by a first thermoplastic polymer film (5', 5”), transparent, with a thickness Ep preferably of at least 20pm and at most 200pm - the lower interlayer (32) with a thickness Ei of at least 20 pm.

2. Method for manufacturing an illuminable laminated glass roof for a vehicle according to the preceding claim, characterized in that the laminate carries the light extraction layer, preferably in the form of a diffusing coating, in particular the light extraction layer is on the lower interlayer or the light extraction layer is on the optical isolator layer which is an optical isolator coating on the first film.

3. Method for manufacturing an illuminated laminated glass roof for a vehicle according to one of the preceding claims, characterized in that, in particular when in the three-layer the first film has a free edge, the method comprises, before lamination: - a joining (195) of a thermoplastic interlayer lamination frame (34) with the three-layer, joining forming local bonds by local softening of the interlayer lamination material, preferably by local heating; preferably the method comprises placing the three-layer on the reference sheet with said interlayer frame joined to the three-layer.

4. Method for manufacturing an illuminable laminated glass roof for a vehicle according to one of the preceding claims, characterized in that it comprises a partial peripheral cutting of the three-layer (203, 101), which is a total cutting over a thickness E' of the first film and of one of the first interlayer and lower interlayer, called the cut layer, leaving a frame surface (31, 321) projecting beyond the other of the first interlayer and lower interlayer, called the whole layer, and in that preferably when E'>200 pm, the method comprises the placement of a lamination interlayer frame on the projecting frame surface.

5. Method for manufacturing an illuminated laminated glass roof for a vehicle according to one of the preceding claims, characterized in that it comprises: - the provision of at least one light redirection element (8), which is transparent on the F4 face side or preferably which is a reflective prismatic film comprising a main face textured with reflective prisms (82, 83) and an opposite main face, called the smooth face, and in that it comprises: - another connection of said light redirection element which is a reflective prismatic film, preferably with a thickness Er<200pm, with the trilayer, another connection forming local bond(s) by local softening of the interlayer material of the trilayer, preferably by local heating, - and / or a pre-bonding of said light redirection element which is a reflective prismatic film, with an interlayer lamination frame, pre-bonding forming local bond(s) by local softening of the interlayer lamination frame, preferably by local heating, preferably, the other bonding and / or the pre-bonding is before placement on the reference sheet, or even before placement on an additional functional element (9) - or the placement of the light redirection element which is a reflective prismatic film on the F3 face, reflective prisms oriented towards the F2 face - or the placement of the light redirection element which is a reflective prismatic film on the F3 face, with gluing on the F3 face via local glue of the reflective prisms oriented towards the F3 face.

6. A method of manufacturing an illuminable laminated glass roof for a vehicle according to the preceding claim, characterized in that the light redirection element is a reflective prismatic film comprising a main face textured with reflective prisms and an opposite main face called the smooth face, preferably a film with a thickness Er <200 pm, with a textured face oriented towards the first interlayer (31), the reflective prismatic film is positioned to be opposite, joined to or offset by at most 4 mm with the first film, in particular: a) before the other joining with the three-layer, bringing said reflective prismatic film into contact with a rear main face of the lower interlayer, the rear main face intended to be oriented towards the face F3, the reflective prismatic film is preferably positioned to be at least partly opposite the first film b) or, before or simultaneously with the joining with the three-layer,the pre-solidarization of the reflective prismatic film, - with a main face of an intermediate lamination frame, - or within an intermediate lamination frame.

7. Method for manufacturing an illuminable laminated glass roof for a vehicle according to claim 5, characterized in that the light redirection element is a reflective prismatic film comprising a main face textured with reflective prisms and an opposite main face called the smooth face, the reflective prismatic film preferably having a thickness Er<200pm and even at least 70pm, and it comprises the placement of the reflective prisms: -on a surface extending beyond the three-layer, after partial cutting of the three-layer, -or on a main face of a lamination interlayer frame -or within an intermediate lamination frame, - or on the F3 face using the local glue binding the F3 face and the reflector prisms oriented towards the F3 face the reflector prismatic film is preferably positioned to be placed next to or offset by at most 4mm with the first film.

8. Method for manufacturing an illuminable laminated glass roof for a vehicle according to one of the preceding claims, characterized in that it preferably comprises, before placement on the reference sheet, preferably which is the second glass sheet, the formation of a so-called complete block comprising: - the provision of an additional stack, called upper block, comprising an additional functional element (9) and a third thermoplastic interlayer lamination layer (33), the additional functional element (9) which is a) an electroactive element, in particular based on liquid crystals, with another interlayer lamination frame (35) on the periphery of said electroactive element, in particular another interlayer lamination frame preferably in local adhesive contact with the third layer lamination interlayer (33), by local bonds, in particular local bonds by local softening of interlayer material, preferably by local heating b) another functional polymer film bonded or in contact with the third lamination interlayer, - on said additional functional element or even on the other intermediate frame, the placement of the laminated laminate with intermediate frame (34) secured to the three-layer and / or light redirection element(s) secured to the three-layer, thus forming a lower block - additional joining of the lower block with the upper block, preferably additional joining forming local bonds by local softening of the interlayer material, preferably by local heating.

9. Method for manufacturing an illuminated laminated glass roof for a vehicle according to one of claims 1 to 7, characterized in that it comprises: - the provision of a third interlayer (33), thermoplastic, preferably in sheet form and even with a thickness of at least 0.3 mm - placement on the third interlayer preferably in this order: - an intermediate lamination frame (34') - an additional functional element, which is an electroactive element, in particular based on liquid crystals or electrochromic or even photovoltaic, or another functional polymer film, - laminated laminate on the additional functional element placed so that the lamination interlayer frame is on the perimeter of both the additional functional element and the laminated laminate, - a joining of said intermediate frame with the laminated laminate and the third intermediate layer, preferably joining forming local bonds by local softening of the intermediate material, by local heating.

10. Method of manufacturing an illuminable laminated glass roof for a vehicle according to one of claims 1 to 7, characterized in that it comprises: on the reference sheet which is the second sheet (2), the placement: - at least one light redirection element (8), in particular a reflective prismatic film with a textured main face and an opposite main face called smooth, placement on the third face of the smooth face or the textured face bonded by interlayer material or by a local glue to the third face, and an interlayer lamination frame (34) - preferably a connection of the intermediate frame (34) with the third face (13) by local connections, in particular by local softening of the intermediate material, preferably by local heating - placement of the functional laminate with the lower interlayer on the third side so that the interlayer frame is on the perimeter of the laminate - preferably a joining of the functional laminate with the third face and even said intermediate frame by local connections, in particular local connections by local softening of the intermediate material, preferably by local heating - placement of the first sheet (1) on the functional laminate and the intermediate frame.

11. Functional laminate, with a thickness of at most 8 mm, comprising a multi-layer assembly characterized in that it includes a laminated three-layer comprising in this order: - a first interlayer of lamination (31), thermoplastic, with a thickness E1 of at least 0.3 mm, in particular based on PVB, in particular with at least 20% plasticizer, - an optical isolating layer (5, 5”) which comprises or is preferably supported by a first thermoplastic polymer film (5') with a thickness Ep preferably of at least 20pm and at most 200pm - a second interlayer of lamination called lower interlayer (32; 32'), thermoplastic, with a thickness Ei of at least 20 pm and even at least 0.3 mm, in particular based on PVB, the laminate carrying a light extraction layer which preferably comprises a diffusing coating.

12. Functional laminate according to the preceding claim, characterized in that the optical insulating layer comprises an optical insulating coating which comprises a matrix with porosities or hollow particles on a main face, preferably the rear face, of the first film, the first film is preferably a polyester film, in particular PET, or polyolefin, with the thickness Ep preferably from 50 pm to 100 pm.

13. Functional laminate according to claim 12 characterized in that the light extraction layer comprises a diffusing coating, the diffusing coating is on the optical isolating coating, directly or on a protective layer.

14. Method for forming a roll of said laminate according to one of claims 11 to 13, in a wound strip, preferably with a width of at least 600mm and / or a length of at most 300mm and optionally comprising a temporary protective film, which comprises: - a first continuous drawing of the optical insulating layer in strip form with said first thermoplastic film, which is preferably a first thermoplastic film carrying an optical insulating coating, - a second continuous print run of the first interlayer in strip form, and in sheet form, having a smooth rear main face with roughness defined by a parameter Rz of at most 50 pm, preferably a second print run separate from the first print run - a third continuous print run, of the lower interlayer in strip form, the lower interlayer having a smooth front face with roughness Rz defined by a parameter of at most 50 pm, in particular a third print run separate from or associated with the second print run, - heating of the first interlayer in strip form - heating of the lower interlayer in strip form when the third print is separated from the second print, the light extraction layer being on the lower interlayer or on the optical isolator layer, in the form of a diffusing coating in one or more diffusing patterns, preferably with a coverage rate of at most 30% - the formation of the laminated laminate by calendering in this order of the first heated interlayer, the first film, the lower interlayer possibly heated - winding the laminated material onto the so-called winding roller.

15. Method for forming a roll of said laminate according to claim 14 characterized in that it comprises: - the unwinding of a roll called the first interlayer unwinding roll comprising the first interlayer layer (31) in strip form, preferably which is based on PVB - unwinding a roll called an insulating roll, comprising the optical insulating layer with said first thermoplastic film (5, 5”, 5'), in a strip, the first thermoplastic film is preferably a carrier on the rear face of the optical insulating coating and of the light extraction layer which is on the optical insulating coating - the unwinding of a roll called a lower interlayer unwinding roll comprising the lower interlayer layer (32) preferably based on PVB, with a thickness Ei of at least 0.3 mm.

16. Method of manufacturing a functional laminate according to claim 14 characterized in that it is roll to roll and comprises: - the unwinding of a roll called the first interlayer unwinding roll comprising the first interlayer layer (31) in strip form, preferably which is based on PVB, in particular with at least 20% plasticizer - the unwinding of a composite roll, comprising a laminated bilayer comprising the optical insulator layer with said first thermoplastic film and the lower interlayer which is based on PVB with at most 5% or 1% of plasticizer, with a thickness Ei of at most 80 pm, having a main face for bonding with the first film and a face opposite the bonding face, the light extraction layer being on the bonding face or the opposite face - said calendering of the bilayer and the first interlayer.

17. Method for forming a roll of said laminate according to one of claims 14 to 16, characterized in that it comprises: - the unwinding of a primitive roll comprising the first thermoplastic film in strip form, in particular a primitive drawing of said first thermoplastic film in strip form - the liquid deposition of a composition called an insulating composition to form the optical insulating coating, preferably during said initial drawing, - the liquid deposition on the optical insulating coating of a so-called extracting composition comprising a matrix and diffusing particles, in one or more patterns, to form the light extraction layer, in particular during said initial printing or in resumption during a subsequent printing - a possible winding of the first film with the optical isolating coating and the light extraction layer in a winding roll, roll unwinding for the second print.

18. Method for forming a roll of said laminate according to one of claims 14 to 16 characterized in that it comprises: - the unwinding of a primary unwinding roll comprising said first thermoplastic film, in strip form, with the optical insulating coating on the rear face, and possibly the lower interlayer - or the extrusion of the lower interlayer, in particular in strip and sheet form, - or the unwinding of a primary roll of interlayer comprising the lower interlayer in strip and sheet form, lower interlayer based on PVB with at most 5% plasticizer, with a thickness Ei of at most 80 pm, and followed by the deposition by liquid means on the optical insulating coating or on the lower interlayer of a composition called an extracting composition comprising a matrix, in particular a crosslinkable one, and diffusing particles, layer in one or more patterns, to form the light extraction layer.

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