Manufacturing of an illuminated laminated glass roof for vehicles with a functional laminate, such a functional laminate and its manufacture

Abstract

The invention relates to a method for manufacturing an illuminable laminated glass roof from a three-layer laminated material (Figure 1).

Description

Title of the invention: MANUFACTURE OF AN Illuminated Laminated Glass Roof FOR A VEHICLE WITH A FUNCTIONAL LAMINATE, SUCH A FUNCTIONAL LAMINATE AND ITS MANUFACTURE

[0001] The present invention relates to the manufacture of an illuminable laminated glass roof for a vehicle with a functional laminate, a functional laminate and its manufacture.

[0002] 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.

[0003] Document WO2021005162 proposes a luminous laminated vehicle roof comprising in its example 2 in relation to [Fig.2] in this order:

[0004] - a first sheet of glass, forming outer glass, tinted coated with a layer low refractive index

[0005] - a first interlayer of lamination, polymer, low index layer side of refraction

[0006] - a second interlayer of lamination, based on polyvinyl butyral (PVB) plasticizer-free, 30pm which is functionalized by being coated with a light extraction layer which is a printed ink comprising TiO2 particles in a polyurethane matrix, ink on the first interlayer side,

[0007] - a second sheet of extra-clear glass forming the inner glass.

[0008] The manufacture of such a roof involves: - 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 - removal of the temporary plastic film - the placement of this second interlayer on the second sheet of glass, printed layer facing upwards - the placement of the first interlayer on the second interlayer.

[0009] The present invention sought to further improve the manufacture of such an illuminable laminated glass roof for a vehicle (speed, reliability, etc.).

[0010] 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, tramways), comprising:

[0011] a curved laminated glazing - transparent (at least in one clear (central) window) - comprising:

[0012] - a first sheet (curved), transparent, in mineral glass, possibly tinted in particular gray or green, intended to form the outer glass, with (a first slice and) a first main face Fl (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 Ipm or 200nm, for a road motor vehicle and even a car, first sheet with a thickness preferably of at most 4mm, or even of at most 2.5mm, even of at most 2.2mm - in particular 1.9mm, 1.8mm, 1.6mm and 1.4mm - and even with a thickness of at least 0.7mm, for example with a refractive index nv of at least 1.5 in the visible

[0013] - a polymer lamination interlayer, transparent (at least in the clear of the glass) (central) - 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 Ipm or 200nm, in the clear of the window) on the face F2, single or multi-layer, in particular if acoustic PVB, or forming an intermediate interlayer, single or even multi-layer), and a second interlayer, called the lower interlayer (clear), thermoplastic (single or multi-layer, in particular if acoustic PVB and the same coating)

[0014] - a light extraction layer, preferably in the form of a coating diffusing comprising a matrix (preferably organic) and diffusing particles, in contact with the lower interlayer

[0015] - a second sheet (curved), transparent (at least in the clear of the glass (central), made of mineral or polymer glass, preferably extra-clear, with a refractive index neither in the visible, with (a second slice 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 of the window, with a thickness of at most Ipm or 200nm, 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 0.7mm (to promote light guidance), possibly with a thickness less than that of the first sheet of glass, even at most 2.2mm - in particular 1.9mm, 1.8mm, 1.6mm and 1.4mm - or even at most 1.3mm or at most 1mm, the total thickness of the first and second sheets preferably being strictly less than 5 or 4mm, even 3.7mm.

[0016] the lower interlayer extends between the first interlayer and the face F3 (and even in adhesive contact with the preferably bare face F3), and the light extraction layer being in contact with the lower interlayer and between the optical isolator layer and the face F3.

[0017] The laminated glass 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 <nl, 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 800nmou Ipm-.

[0018] The method comprises in this order:

[0019] - an assembly step comprising:

[0020] - a placement on one of the first and second sheets called sheet of reference 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),

[0021] - a positioning of the other of the first and second sheets, called the other sheet,

[0022] - a lamination (of a glazed assembly comprising between the first and second sheets, lamination interlayer, optical isolator layer, light extraction layer etc.).

[0023] 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:

[0024] - the first interlayer of thickness E1 preferably of at least 0.3 mm and better at most 0.9mm or 0.6mm, in particular based on a first polymer (in particular based on PVB with at least 20% plasticizers)

[0025] - said optical isolator layer (recessed and encapsulated by the first layer in intercalary and the lower intercalary layer or with a free edge), said optical insulating layer comprising (even consisting of) or being supported by a first thermoplastic polymer film (non-adhesive, in particular polyester or polyolefin) with a thickness Ep of at least 20pm, 30pm or 40pm and preferably at most 200pm, or better 125pm or even 100pm or 75pm (chosen according to its rigidity to facilitate the manufacture of the three-layer)

[0026] - the lower interlayer of thickness Ei preferably at least 20 pm or 25pm, preferably based on a second polymer identical or similar to the first polymer (in particular PVB (usual) plasticized with at least 20% plasticizers or TPU or EVA preferably Ei of at least 0.3mm or based on PVB (low plasticization or without plasticizer) with at most 10% or 5% or 1% plasticizers and preference Ei is at most 100pm or 80pm or 50pm), in particular we define a thickness E'= Ei+Ep,

[0027] Furthermore, the laminate preferably carries the light extraction layer, in the form of a diffusing coating, in the form of one or more diffusing patterns (in the clear view), 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)).

[0028] The invention simplifies and makes the manufacturing process of the illuminated roof more reliable in several respects.

[0029] First of all, the fact of producing the functional laminate upstream makes it possible to position only one element on the reference sheet rather than proceeding sheet by sheet.

[0030] 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.

[0031] Furthermore, the three-layer incorporating the optical isolator layer makes it possible, 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, controlling the thickness of the optical isolator film or the optical isolator layer coated on the first, flexible, flat film is easier than coating on the first curved glass sheet.

[0032] 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 an optical isolating coating). In particular, it may be desirable not to weaken the F3 face by a coating.

[0033] Furthermore, with the three-layer rather than the sheet-to-sheet process, it is possible to laminate glasses of greater complexity without creases being generated by the lamination in the interlayers.

[0034] Furthermore, with the three-layer rather than the sheet-by-sheet process, the degassing is already partly done during the phase of the formation of the three-layer.

[0035] 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 may be available in roll or sheet form.

[0036] The first individual and thin polymer film would be:

[0037] -difficult to handle, with the risk of flying away because it is too light

[0038] -subject to tearing when robots transport it, or to cutting

[0039] -creasable, in particular marking folds and bumps when cutting (when suctioning on the cutting machine to the shape of the glazing etc.).

[0040] Unstacking it in sheets or removing it from a roll would make it very electrostatic so that it attracts and traps dust, requiring working in a very clean environment or adding another electrostatic discharge step that cancels out the electrostatic forces plating the dust on the first film.

[0041] 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 a roll does not mechanically alter the first polymer film or degrade the optical insulation function or the transparency.

[0042] Handling problems can also arise with the lower interlayer alone (in sheet form) which can be as thin as 20 pm, in particular functionalized by carrying the light extraction layer.

[0043] Furthermore, the thicker first interlayer facilitates crease-free cutting and crease-free placement not only of the first film but of a possibly thin lower interlayer.

[0044] Furthermore, all layers of the tri-layer (of the laminate) are precisely positioned at the same time on the reference sheet. In particular, in a sheet-by-sheet 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.

[0045] 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).

[0046] In addition, the quality of the laminate can be easily controlled, further upstream in the manufacture of the roof, without sacrificing glass sheets.

[0047] The proposed solution therefore consists of preparing the functional laminate with the laminated trilayer (and even laminate provided 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.

[0048] Once the laminated tri-layer (or even a laminated multi-layer greater than 3 layers) is ready, it can be:

[0049] - placed on the reference sheet in particular the second glass sheet

[0050] - 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, electrochromic, photovoltaic etc.), 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).

[0051] If necessary before placement on the reference sheet, preferably the second glass sheet (face F3), the laminated three-layer is cut (partially or completely) and / or bonded with an interlayer frame at its periphery (of contour to the shape of the glazing).

[0052] 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 comprise 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 the electroactive element is not necessarily the same size as the first film.

[0056] The thickness El of the laminate may be at most 8mm or even at most 6mm. The length L1 of the laminate may be at least 600mm and better still at most 2000mm. The width W1 of the laminate may be at least 600mm and better still 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 wound 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 interlayer adhesive material.

[0059] It is at least 0.3 mm 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).

[0060] Of course, it is possible that in the laminated laminate before placement on the reference sheet as after laminating the glazing:

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

[0062] - the possible interface between an intermediate frame and first intermediate layer or lower interlayer is indistinguishable (especially if based on the same material and the same color)

[0063] - the possible interface between layers (sheets) of a multi-layer interlayer frame be indistinguishable (especially if made from the same material and the same shade)

[0064] Preferably the laminated three-layer is preferably obtained from at least 2 sheets: the first film and the first interlayer, in sheet form, and even from 3 sheets with the lower interlayer.

[0065] The reference sheet is preferably the second (inner, curved) sheet and presented with its convex surface facing upwards because 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.

[0066] Alternatively, the reference sheet is the first (outer) sheet and shown with its concave surface facing upwards.

[0067] 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.

[0068] The lamination (of the glazed assembly, to form the laminated roof) is carried out at appropriate temperatures and pressures, (for example, in particular for interlayer of PVB-based lamination (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.

[0069] The lamination may comprise 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.

[0070] In a step consisting of heating the glazed assembly by subjecting it to a vacuum, an additional external pressure is not simultaneously applied to it, as for example in an autoclave.

[0071] When the glazed assembly is subjected to a vacuum, there is sealed confinement of the entire periphery of the glazed assembly and suction in the confined peripheral volume.

[0072] The glass assembly is for example subjected to a vacuum by means of a vacuum chamber or a vacuum bag.

[0073] For lamination, for example, a sealed elastomer envelope is fitted over the entire peripheral part of the glazed assembly, provided with an orifice through which a vacuum is created by suction. The sealed envelope is often referred to by the English term "vacuum ring". Suction is therefore applied to evacuate the air present between the two sheets of cold glass for a period of 15 to 45 minutes, then heating is carried out to a temperature of 80°C to 120°C for a period of 30 to 60 minutes.

[0074] An alternative to this last vacuum step may consist of placing the glazed assembly in a vacuum enclosure or a vacuum bag of which at least part of the walls is rigid so as to protect any peripheral element of the glazed assembly by preventing it from being subjected to physical contact under excessive mechanical stress.

[0075] As a peripheral element, mention may be made of an electrical connection element which is connected to an electroactive (electro-optical) element, in particular based on liquid crystals or electrochromic or even photovoltaic, between the two sheets of glass. For example, such a connection element or other is between the two sheets and extends outside the glazed assembly (for example along the edge of the glazed assembly).

[0076] 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 problems of sealing the edges, a lack of adhesion for the total glazing, water infiltration and oxidation.

[0077] In the present invention for each layer (film, sheet, in particular interlayer; first film, trilayer 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 face F3, and the front main face is understood to mean the face which is or is intended to be oriented towards face F2.

[0078] Advantageously, in particular when in the three-layer the first polymer film has a free edge, the method comprises before lamination (of the glazed assembly):

[0079] -a joining (which is preferably an adhesive contact) - preferably direct, without the addition of additional adhesive -, of a thermoplastic lamination interlayer 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, joining 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),

[0080] in particular joining by (local) softening of interlayer lamination material (of the frame and / or of the three-layer), preferably by local heating.

[0081] (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 lamination frame / interlayer).

[0082] Local connections are made, in particular spot welds, preferably following (or delayed) the contact (or at most 5 mm or 1 mm in the case of local heating) of the frame with the three-layer, possibly with a cut-out part of the three-layer (cut-out layer).

[0083] Preferably:

[0084] - 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),

[0085] - local connections preferably at least 1mm or 5mm long and at most 30mm long or 15mm and spaced at least 10 or 15cm apart and even at most 80 or 50cm apart.

[0086] During said lamination, the free edge of the first film is encapsulated by lamination interlayer material.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] Advantageously, the joining (the adhesive contact) is by local heating and possibly also by pressure, in particular induction heating, by hot air, by radiation (laser).

[0091] As a local and even multi-local heating tool (and better pressure) one 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.

[0092] The temperature and pressure are adjusted according to the interlayer material (preferably PVB) and the tool.

[0093] 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.

[0094] 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 three-layer and on either side of the boundary. For example, a heating finger (10 mm) is centered alternately on the three-layer (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 provide for the various local connections, here between frame / three-layer (or any other joining with several local connections described later), in a single operation.

[0095] Thus, the joining (adhesive contact), here of the frame with the three-layer, can be in one operation for all the local connections. It is possible to choose a heating tool which allows the various point adhesive points to be made in a single operation, for example via heating fingers.

[0096] Local heating can be by applying a heating tool to the front face of the laminate (towards face F2) and / or to the rear face.

[0097] This joining is preferred to gluing using a bead of glue or double-sided adhesive, possibly punctual.

[0098] 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.

[0099] The intermediate frame can be:

[0100] - single layer (sheet) clear or tinted or even opaque

[0101] - multilayer (multi-sheet) in particular with first and second sheets of color distinct, in particular the so-called upper sheet (oriented towards face F2). opaque (for light masking etc.).

[0102] Local heating can make it possible to form not only local adhesive contact between two elements but also to join together two by two a stack of several layers, sheets.

[0103] The interlayer frame is not always necessary to protect the first film, in particular when in the three-layer Ep is at most 200 pm and even at most 150 pm or 100 pm and the first polymer film is shorter (for example at least 3 mm, or 5 or 10 mm and at most 30 mm (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 view by reducing its extent etc.

[0104] Advantageously, the method comprises placing on the reference sheet the three-layer with said integral interlayer frame (linked by the local bonds).

[0105] For example, the method comprises: - 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) - - joining the laminate and the intermediate frame so that the edges of the frame and the laminate are locally joined - placement of the laminate assembly linked to the interlayer frame on the reference sheet (with centering in relation to it), - 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.

[0106] During lamination, care is taken to ensure that any interlayer material extends sufficiently and is correctly thin to avoid breakage and bubbling phenomena. In particular, any functional element (first film, other functional polymer film, electroactive element, etc.) with a thickness of at least 200 μm intercalated between two interlayers and shorter is preferably surrounded by an interlayer frame between the two interlayers.

[0107] In particular, in the assembly process (with autoclaving), the material in- interlayer (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: - breakage of one of the two glasses, due to excessive deformation of the latter, inducing excessive local extension constraints; - bubbling introduced into the glazing, due to imperfect finishing 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.).

[0108] 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.

[0109] To limit the risks of breakage or bubbling, the method further comprises, when E' > 200 pm and even E' > 150 pm or even E' > 100 pm, the placement of an interlayer frame (to be more easily handled without folds etc., preferably with a width Wc of at least 20 mm, in particular Wc less than or equal to the width Wl, and / or with a thickness Ec of at least 0.3 mm) on the protruding frame surface. In particular, during lamination, the first film is encapsulated by lamination interlayer material.

[0110] 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).

[0111] This intermediate frame can be used:

[0112] -to protect the free song of the first film as mentioned above

[0113] -and / or to arrange at least one functional element (light redirection element(s) etc.) near the three-layer.

[0114] - and / or being tinted and even opaque (to eliminate stray light etc.).

[0115] 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 called 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).

[0116] During lamination the first film is encapsulated (coated) by in- intercalary (by creep of the intercalary frame and / or the entire layer).

[0117] In particular when the rear (free) face of the lower interlayer does not carry the light extraction layer, the lower interlayer in particular based on PVB with at least 20% plasticizers, it may be desirable for the rear (free) face of the lower interlayer to have minimal roughness, promoting degassing, satisfactory lamination. In particular the roughness parameter Rz is at least 100 pm or even 50 pm.

[0118] In particular based on PVB with at least 20% plasticizers, it may also be desirable that the front (free) face of the first interlayer (oriented towards the face F2 after placement on the reference sheet) has minimal roughness, promoting degassing, satisfactory lamination. In particular the roughness parameter Rz is at least 100 pm or even 50 pm.

[0119] When E'< 200pm and better at most 150pm or 100pm and the entire layer is the first interlayer with a thickness of at least 0.3mm, during lamination the entire layer thins and encapsulates (coats) the first film.

[0120] It is also possible to carry out a total cutting of the 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 carry out a total cutting of the three-layer (preferably before any local bonding of the three-layer with another element such as the intermediate frame, etc.) to a predetermined shape.

[0121] Preferably, an automatic cutting system is implemented, 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 orifices in the belt.

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

[0127] In particular in a first configuration:: - the edge of the lamination interlayer has an overhang of between 5 and 20 mm compared to the edges of the glass sheets, - the process includes trimming of the interlayer material before degassing (i.e. cutting of the interlayer material to be edge to edge with the glass sheets) - after autoclave, the process includes brushing (removing) excess interlayer material from the edge of the glass sheets.

[0128] In particular in a second configuration, the edge of the lamination interlayer has a shrinkage of 0 to 4 mm relative to the edges of the glass sheets.

[0129] The second configuration is preferred because:

[0130] - have the edge of the interlayer slightly set back from the edge of the glass limit light leaks through the glass edge,

[0131] - the first and second slices (of the glass sheets) are preferably in subsequently encapsulated, 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

[0132] - not having to do any deburring or brushing avoids operations and therefore yield losses,

[0133] - deburring and brushing a thick multi-layer of interlayer is more complex.

[0134] The method may further comprise:

[0135] — the provision of at least one light redirection element, in particular in pe edge 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) preferably which is a reflective prismatic film comprising a main face textured with reflective prisms and an opposite main face, called smooth face (non-textured),

[0136] - another joining (which is preferably an adhesive contact) of 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 joining forming local bond(s) by local softening of the interlayer material of the trilayer, preferably by local heating,

[0137] - and / or a pre-solidarization (which is preferably an adhesive contact) of said light redirection element (light redirected towards the F3 face) 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 securing already described), in particular pre-bonding forming local bond(s) by local softening of the interlayer lamination frame, preferably by local heating

[0138] 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.

[0139] 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 or 2 or 3 local connections are made.

[0140] The light redirection element is preferably of thickness Er < 200pm and even at most 150pm, to avoid the addition of an interposed frame, and is preferably a reflective prismatic film.

[0141] The (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). The local connections, in particular spot welds, are made preferably following (or delayed) the contact (or close to at most 5 mm or 1 mm if local heating) of the light redirection element with the interlayer material.

[0142] 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.

[0143] In particular during said lamination (of the glazed assembly) the light redirection element is encapsulated by interlayer material.

[0144] The light redirection element 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 by total reflection. The light redirection element is elongated to receive light for example from a row of diodes (rectilinear bar preferably at least 5 cm, in one or more sections, connected or not).

[0145] Preferably, the light redirection element is a reflective prismatic film at least 1 cm wide and at most 5 cm long, comprising a flat face and a face with reflective prisms (monolithic film or with textured coating, such as an embossed resin).

[0146] In order to avoid folds and undulations, the first film and / or the prismatic film (reflector) 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.

[0147] The light redirection element (the reflective prismatic film) preferably has a thickness Er of less than 200 pm and even at most 150 pm or 100 pm to avoid the addition of a dedicated interposed frame surrounding it.

[0148] The substrate film or base of the (micro)prisms can be less than 200pm, 100pm, 80pm or 50pm and even at least 30pm. For example, it is a film (polyester, PET) which can be tinted and even opaque if the prisms are oriented towards the third face F3.

[0149] The prisms may have a height of at least 1 pm and preferably at most 100 or 50 pm or 30 pm.

[0150] Preferably, the prismatic (reflecting) part of the reflective prismatic film is on, or even in contact with, the interlayer material (of the first interlayer, of the lower interlayer, of the frame) to protect the peaks, 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 still 50 μm or 100 μm is preferred).

[0151] The light redirection 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.

[0152] The (first) reflective prismatic 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). It is possible to have several reflective prismatic films abutting or disjointed along a first edge.

[0153] 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.

[0154] 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 isolating 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

[0155] a) before the other attachment to the trilayer, contacting (laying) said reflective prismatic film (of the smooth face, here the rear face) on a rear main face of the layer lower insert,intended to be oriented towards the face F3, the prismatic reflective film is preferably positioned to be at least partly opposite the first film,

[0156] 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)

[0157] 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):

[0158] - with a main face (front or rear) of a lamination interlayer frame

[0159] - or within an intermediate lamination frame, in particular multi-layer (multi-layer), preferably based on plasticized PVB (with at least 20% plasticizer).

[0160] The reflective prismatic film may be under the first film or adjacent to the first film, possibly slightly offset in height (towards face F2) with the first film.

[0161] 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).

[0162] 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 intermediate 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 interlayer lamination frame or of a third interlayer lamination layer or of the first interlayer layer.

[0165] In a second 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 attached then as already explained), in particular the main front face intended to be oriented towards face F2

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

[0169] The thickness of the interlayer material 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 400pm (in particular PVB with at least 20 or 30% plasticizers and even without, at least 350pm).

[0170] Preferably the smooth face is further bonded to an interlayer material of another lamination interlayer frame or of a third lamination interlayer (of said lamination interlayer).

[0171] The reflective prismatic film may be under the first film or adjacent to the first film, possibly slightly offset in height from the first film.

[0172] When the reflective prismatic film is positioned to be adjacent to the first film, attached to or at most 4 mm or 1 mm apart from the first film, then preferably the bases or the tops of the reflective prisms (oriented towards the lower interlayer, towards the face F3) are preferably above at most 30 pm (from the front face) of the first film or even the optical isolating coating (in redirection of the face F2).

[0173] Before lamination, the textured face is oriented (the reflecting prisms) is oriented towards the F3 face.

[0174] Alternatively, the light source is opposite the edge of the second sheet or is on the F4 side and coupled to a light redirection element in transmission on the F4 side (prism, prismatic film, etc.).

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

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

[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 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 comprise 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 intermediate frame secured to the three-layer, in contact or better secured (locally) to the upper block (by softening of the intermediate material, for example an intermediate frame and / or other intermediate 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 lamination interlayer (of said lamination interlayer), preferably plasticized PVB (at least 20% plasticizer)

[0182] the additional functional element which is:

[0183] a) an electroactive (electro-optical) element, in particular based on liquid crystals or electrochromic or even photovoltaic (with solar cells), with another intercalary lamination frame on the periphery of said electroactive element, in particular another intercalary lamination frame preferably in local adhesive contact with the third intercalary lamination layer, by local bonds, in particular local bonds by local softening of intercalary material, preferably by local heating

[0184] 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:

[0185] - on said additional functional element or even on the other intermediate frame, the placement of the laminated laminate with an interlayer frame secured to the three-layer and / or light redirection element(s) secured to the three-layer, thus forming a lower block

[0186] - an additional connection of the lower block with the upper block of preferably additional joining forming local bonds by local softening of intercalary material, preferably by local heating.

[0187] In one embodiment, the method may comprise:

[0188] - 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

[0189] - placement on the third interlayer preferably in this order:

[0190] - of an intermediate lamination frame (34')

[0191] - of 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,

[0192] - of the three-layer (or of the laminated laminate, in particular consisting of the three-layer) on the additional functional element

[0193] placement so that the lamination interlayer frame is both on the periphery of the functional additional element and of the three-layer (of the laminated laminate),

[0194] - a joining (preferably by adhesive contact) of said frame in interlayer with the laminated laminate and the third interlayer, preferably so- lidarization forming local bonds by local softening of intercalary material, by local heating (as already described).

[0195] In one embodiment, the method may comprise:

[0196] on the reference sheet which is the second sheet, the placement: - 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 - 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 - placement of the three-layer (functional laminate) with the lower interlayer on the third side so that the interlayer frame is on the perimeter of the three-layer (functional laminate) - preferably a bonding (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 the interlayer material, preferably by local heating - placement of the first sheet on the functional laminate and the interlayer frame.

[0197] It is thus possible to prepare in parallel (or in sequence on the same editing table)

[0198] - the additional stacking, the upper block (cutting, local connections with other interleaved frame for lamination etc.)

[0199] -and the laminate with interlayer lamination frame and / or redirection element(s).

[0200] It is preferred to bring the laminate (lower block) and the additional stack (upper block) into contact, to secure them (locally) before placing them on the reference sheet.

[0201] It is particularly 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 on the second sheet (face F3) which is the reference sheet.

[0202] Indeed, in the case of an additional stack which comprises an electroactive element with an intermediate frame secured by local bonds to the third intermediate layer, 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.

[0203] 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 joinings.

[0204] In order for the different elements to remain firmly attached and positioned relative to each other during the rest of the process, it is also possible to provide for attachment by local connections, (local) softening of the intercalary material: - 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) - 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 preferably bare face F3 or with a functional coating (electroconductive, transparent, etc.) on the face F3.

[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 of the complete block is under a peripheral masking frame, for example in black enamel on face F2 and / or black ink on the third interlayer.

[0208] The light extraction layer is preferably a diffusing coating which is:

[0209] -between the optical isolator layer and the lower interlayer with a coverage rate preferably of at most 30% (for cohesion).

[0210] -on the rear face of the lower interlayer (F3 face side) with a coverage rate preferably of at most 30%, at most 25%, 10% (for cohesion).

[0211] Each interlayer of lamination made of thermoplastic polymer material can be chosen from polyvinyl butyral (PVB), or even polyvinylacetate (PVA), ethylene-vinyl acetate (EVA), 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 level of plasticizer, branching / linearity, average molecular mass of the molecules, etc.

[0212] Of course, it is preferable that each interlayer of the laminate be based on the same thermoplastic polymer (plasticized or not, tinted or not, etc.).

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

[0214] - the outermost interlayer, i.e. in contact with the bare face F2 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 face F3).

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

[0217] The lower 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 the same size 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 reflective prismatic film) are masked from the outside by a peripheral masking frame and even from the inside, for example, by a trim.

[0221] Examples of electro-optical elements are SPD elements (SPD = Suspended Particle Device), known for example from 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.

[0222] Typically, the two electrodes are arranged between two carrier films, usually made of PET. Commercially available multilayer 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.

[0223] In a particularly preferred embodiment, the liquid crystal element is a PDLC (polymer dispersed liquid crystal) element. The PDLC element contains liquid crystals that are embedded in a polymer matrix. 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 element . PDLC, we are talking about the application of a voltage, so an alternating voltage (the effective value of the alternating voltage and not the instantaneous voltage) is intended for the purposes of the invention.

[0224] For example, the blur in the diffusing state of the roof with a PDLC layer is at least 80% and better 85%, 90%, 95%.

[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, EC, solar, functional film) may 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 may be aligned or separated by at most 10 cm or 5 cm or 1 cm.

[0229] The glazing may therefore comprise 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 (based on PVB and with a coloring agent) on a main face of a PVB on the second or third face side.

[0230] The internal masking layer may 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.) in particular 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 in particular delimits 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, that the frame layer is 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 the rear.

[0232] In particular, another masking layer, called the inner 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 mineral glass sheet). It may be adjacent to a possible transparent functional coating, in particular athermal, at least in the clear of the window.

[0233] In particular for an automobile roof (first sheet is the exterior glazing):

[0234] - the width of the internal (and even inner) masking layer along the edges longitudinal can be at most 30cm, especially 10-20cm.

[0235] - the width of the internal (and even inner) masking layer along the edge rear side may be at most 40cm or 30cm, in particular at least 1 or 5cm, and along the front side edge at most 60cm or 40cm, in particular at least 1 or 5cm.

[0236] Preferably, concerning the light extraction layer, 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.

[0237] Preferably, the diffusing particles are chosen from non-luminescent particles of TiO2, SiO2, CaCO3, ZnO, Al2O3, ZrO2. 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).

[0238] 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:

[0239] - a first interlayer of thermoplastic lamination, of thickness El of preferably at least 0.3mm (single or multi-layer, especially if acoustic PVB) and preferably no more than 1.2 mm

[0240] - an optical isolator layer which comprises or is supported by a first film thermoplastic polymer with a thickness Ep of at least 20 or 50 pm and at most 200 pm or 125 pm or 100 pm

[0241] - a second interlayer of lamination called lower interlayer, thermoplastic, with a thickness Ei of at least 20 pm, (single or multi-layer, in particular sheet if acoustic PVB) and preferably at most 1.2 mm

[0242] the laminate preferably carrying a light extraction layer preferably which comprises and even in the form of a diffusing coating (on the lower interlayer, on the front face (optical isolator layer side) or opposite rear face).

[0243] In a first configuration, the optical isolating layer comprises an optical isolating coating, preferably on a main face, preferably the 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.

[0244] The first film, preferably PET, has:

[0245] -an adhesion with the first interlayer and / or with the lower interlayer of at least 2N / m and even at least 3N / m,

[0246] - a roughness parameter Rz of at most 50pm (in particular for the main face preferably rear coated with an optical isolating coating).

[0247] A light transmission of the first film (and the lower interlayer) of at least 90%, a haze of at most 0.5% (measured in transmission according to ASTM D 1003) is preferred.

[0248] 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.

[0249] Preferably the optical isolating coating is:

[0250] - a hard layer (hard coat), thanks to its matrix, - in particular which is not likely to be damaged by lamination by calendering the laminate,

[0251] Thus the optical isolating coating has a hardness of at least 1H

[0252] If necessary it is covered by a (more) hard protective coating, for example organic, transparent for example a dense layer in the same matrix as the optical isolating coating, preferably with a thickness of at least Ipm.

[0253] Advantageously, to further increase the luminance:

[0254] -the difference in refractive indices nl-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,

[0255] -the thickness of the optical isolating coating is at least 800nm, 900nm, lpm and preferably less than or equal to one of the following values: lOpm, 5pm, 3pm, 2pm.

[0256] For mechanical strength (in particular if low index nanoparticles or porosities in the optical insulating coating) and / or depending on the availability of the products (less easy at very low index), one may want to limit the difference in refractive indices nl-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 ni from 1.5 to 1.53).

[0257] The optical isolating coating may comprise at least 99% by weight of crosslinked polymer, optional photoinitiators, rheological agents.

[0258] The optical isolating coating is preferably deposited liquid-based.

[0259] The surface of the optical isolator coating (before assembly) is non-sticky and involving the use of lamination interlayer. The surface is then particularly non-sticky to glass, to the touch.

[0260] The optical insulating coating is in particular a varnish which can be obtained from a photocrosslinkable resin and with photoinitiators if necessary or even thermocrosslinkable, 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.

[0261] 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,

[0262] - or even silicone (for example with a refractive index of at most 1.4 or 1.3) including polydimethylsiloxane, epoxy polymer, polyepoxides, polyurethane, polyvinyl acetate, polyester.

[0263] Preferably the optical insulating coating is free of free silicone, volatile silicone component (source of surface pollution).

[0264] The crosslinked polymer material (of the optical insulating 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 insulating coating to be a polymer preferably based on acrylate, urethane acrylate, or even silicone, silicone acrylate, the polymer also having a fluorinated function.

[0265] The optical isolating coating according to the invention may in particular be a coating obtained by liquid means and obtained from a formulation preferably photo-crosslinkable by ultraviolet UV (in particular UVA) or even 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.

[0266] In a first example of an optical isolating coating, a crosslinkable UV resin based on acrylates is deposited on the first polymer film.

[0267] 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.

[0268] In a third example of an optical isolating coating, a silicone-based crosslinkable UV resin is deposited on the first polymer film.

[0269] The optical insulating coating (clear or tinted) may comprise, or even consist of, a matrix with a refractive index n2m greater than n2 and less than n1 or n' 1, and with n2m preferably 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 particles, with a size (external diameter) of at most 300nm or even at most 100nm, for example hollow silica nanoparticles. Preferably, the optical insulating coating is free of free silicone or volatile silicone component (source of surface pollution).

[0270] The matrix may be organic, in particular 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.

[0271] The low index polymers already described can be cited if we want to further lower n2.

[0272] 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%.

[0273] 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).

[0274] 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.

[0275] For example, the matrix of the optical isolating coating is a polymer and a protective coating (in contact or even deposited on the optical isolating coating) is a chemically compatible polymer (identical or similar polymer).

[0276] 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).

[0277] In a second configuration, the optical isolator layer is a fluoropolymer film with an Ep preferably of 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

[0278] 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).

[0279] The light extraction layer may in particular be:

[0280] - a diffusing coating (matrix with diffusing particles) on the coating optical isolator with a possible protective overlayer (dense) of the optical isolator coating (porous etc.).

[0281] Preferably the diffusing coating is:

[0282] - a hard layer (hard coat), thanks to its matrix, - in particular which is not likely to be damaged during lamination (by calender) of the laminate,

[0283] - is not likely to stick (to the calender, to the roller of a roll to roll process roller etc), for example a varnish (anti stack)

[0284] Thus the diffusing coating has, for example, a hardness H of at least 1H.

[0285] In particular, the lower interlayer may be based on PVB with from 0% to 15% or 10% or 5% of plasticizers, with Ei of at most 50 pm and carries the diffusing coating on the main front or rear face.

[0286] 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 films functional transparencies (electroconductive, passive, sandwiched between two interlayers) and / or an electroactive element (in particular based on all-solid electrochromic).

[0287] In particular, the laminated multilayer comprises:

[0288] - the three-layer (linked to a possible frame)

[0289] -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)

[0290] - a third interlayer of lamination.

[0291] Any electroactive element capable of undergoing lamination by calendering 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 electrochromic layer of all-solid technology / 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 TITO, silver stack etc.).

[0292] The laminate may comprise the laminated trilayer or even comprise a multi-layer with at least 4 or 5 layers, preferably at most 1 or 2 additional intercalary layers, an electroactive element (in particular based on liquid crystals or electrochromic or even photovoltaic).

[0293] In particular, the multilayer comprises

[0294] - the laminated three-layer (linked to a possible frame)

[0295] - an electroactive element (with a possible other frame)

[0296] - a third interlayer (upper interlayer), integral with the three-layer.

[0297] It is preferable to avoid lamination by calendering for certain electroactive systems, in particular based on liquid crystals, solar cells.

[0298] The laminated functional laminate may comprise an interlayer lamination frame on the periphery of the trilayer (of the multilayer) and locally in adhesive contact with the trilayer.

[0299] The laminated functional laminate may comprise at least one redirection element of light (as already described), in particular of thickness Er < 200pm and even at most 150pm and better at least 70pm and in particular of the interlayer material (of the trilayer and / or of 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.

[0300] The cut laminate may have a protruding frame surface filled by an intermediate frame of variable color, possibly opaque over all or part of its thickness.

[0301] 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 in front of Fl, passing through the reflective film (imperfect).

[0302] 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 face F2.

[0303] The laminate carrying the light redirection element may comprise an opaque zone (opaque coating, black ink) opposite the light redirection element, between the prisms and the face F2.

[0304] 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.

[0305] Finally, the invention relates to a method for manufacturing a functional laminate which comprises the formation of a roll of said laminate as described previously in a roll method.

[0306] This involves the manufacture of the layers of the trilayer, for example:

[0307] - an extrusion of the first interlayer (in sheet),

[0308] - 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.),

[0309] - the formation of the insulating coating on the first coated film preferably in line (roll or roll for example)

[0310] This also involves the deposition of the diffusing coating preferably in line (roll to roll for example).

[0311] Forming a roll of said laminate may involve:

[0312] - a continuous roll-to-roll process, starting from several rolls of sheets going to the laminate roller, therefore a single roll(s) to roll process

[0313] - a roll process resulting from several roll-to-roll processes in succession and / or forming rolls from extrusion(s).

[0314] preferably the speed is at least 1 or 10 or 20m / min.

[0315] Thus the invention aims at the formation of a roll of functional laminate, in particular a roll-to-roll method, comprising:

[0316] - a first continuous drawing of the optical isolator layer in strip, 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 a first thermoplastic film, in particular polyester (preferably PET), bearing an optical isolating coating (for example a hard layer or "hard coat" in English or even with a hard, transparent protective coating, compatible with the lower interlayer),

[0317] - a second continuous drawing of the first interlayer in strip, and in sheet, 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 run separate from the first print run (first interlayer and optical isolator layer are two independent strips, running separately)

[0318] - a third continuous drawing of the lower interlayer in strip (in 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 third print run separate 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)

[0319] - heating of the first interlayer (with a temperature adjusted in function of the intercalary material),

[0320] - heating of the lower interlayer (independent strip or strip composite), (with temperature adjusted according to the interlayer material) when the third print is separated from the second print

[0321] 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%,

[0322] - the formation of the laminated laminate by calendering (pressing by passing 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),

[0323] - winding the laminated laminate onto a roller called a winder.

[0324] It is preferred to produce the laminated laminate by a roller process rather than an as- sheet-by-sheet assembly then lamination by autoclave to improve the handling of thin films in the roof manufacturing stages, limit the risks of pollution on thin films, limit folds, for less waste.

[0325] It is also preferred to use one or more rolls rather than pre-cut sheets conveyed before the calender.

[0326] The method of forming a roll may further comprise inserting into the calender (to form the laminate):

[0327] - of a third interlayer, in sheet, from another roll, with a preheating (upstream of calendering),

[0328] - an electroactive (electro-optical) element, such as an all-electrochromic element solid, in strip form (from a roll) or in cut sheet, or from a functional polymer film

[0329] - or even a laminated functional bilayer comprising a third layer interlayer in adhesive contact with an electroactive element or a functional polymer film (thermoplastic, in particular polyester, PET).

[0330] preferably in this order:

[0331] the third interlayer (independent sheet) optionally heated, the electroactive element or the functional polymer film, the first interlayer heated, the first film, the lower interlayer (optionally heated, independent sheet)

[0332] or the laminated functional bilayer, the first heated interlayer, the first film, the lower interlayer (optionally heated, independent sheet).

[0333] Heating the interlayer material serves to make the interlayer sticky for adhesion with the first film (with or without optical isolating coating, diffusing coating) or other film (non-adhesive, PET etc.),

[0334] - in particular if based on PVB (plasticized), heating the first layer in intercalary is preferably at least 50°C or 60°C and at most 120°C

[0335] - 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

[0336] - in particular if based on PVB (preferably plasticized, usual PVB), heating possible of the third lower interlayer is preferably at least 50°C or 60°C and at most 120°C.

[0337] Calendering, preferably at room temperature, is most rapidly after heating, for example less than 10s or 5s.

[0338] Cooling of the functional laminate in strip form (after calendering) can be provided before winding, by passing it over a cooled roll(s) for example.

[0339] 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.

[0340] To make the unwinding of the strips more reliable, swelling mandrels can be used.

[0341] The rollers of the calender can be metallic, polymer (rubber) or one metal, the other polymer (rubber).

[0342] 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.

[0343] The face of the lower interlayer coated with a diffusing coating is preferably smooth.

[0344] The extraction layer may be a hard coat with sufficient hardness (at least 1H) to be in contact with the calender.

[0345] Apart from temperature, the parameters of a roll process (or even strips from extruder(s) and a possible roll) include the following:

[0346] - the tension (in N / m) of the first interlayer (possibly single sheet or multi-sheet 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).

[0347] - and / or the tension (in N / m) of a first film / interlayer bilayer in lower (or first film / first interlayer) controlled so as to unwind the bilayer correctly, maintaining the tension to ensure that the strip is held securely across the entire width, while avoiding elongation of the material(s).

[0348] - the (linear) pressure applied by the calender, preferably at most 3500 N / m.

[0349] It is possible to provide (retro)control of the tensions, the heating(s), the pressure

[0350] It is possible to use several rollers before and after the calender in particular:

[0351] - to stretch and avoid creases one or more guide rollers (number depending on the material), in particular a guide roller for the first film (if PET in particular), one or more (three) guide rollers for an interlayer of lamination (PVB in particular).

[0352] Heating can be done by:

[0353] - IR infrared lamp (e.g. IR absorbing sheet material, generating the heating), in particular a plurality of IR lamps (tubes etc.) transverse to the direction of drawing over the width of the strip in question, in particular IR resistors,

[0354] - hot air

[0355] - microwave

[0356] - passage between heated rollers.

[0357] In particular, the method of forming the roll comprises a total pre-cutting on one or both free edges of the strip after calendering and before winding, and even followed by a side cut to move, store, transport the winding roll.

[0358] In one configuration, the three aforementioned prints (optical isolator layer, first interlayer, lower interlayer) are distinct.

[0359] 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 aforementioned prints before calendering for the trilayer).

[0360] In a first embodiment, the method of forming the roll (is roll to roll) and comprises for the (three) prints:

[0361] - (for the first draw) the unwinding of a roll called the first roll interlayer comprising the first interlayer in strip form

[0362] - (for the second draw separate from the first draw) the unwinding of a roll called insulating roll comprising the optical insulating layer (low index) with said first thermoplastic film in strip form, the first thermoplastic film is preferably a carrier on the back side of the optical insulating coating and the light extraction layer which is on the optical insulating coating

[0363] - (for the third draw separate from the first and second draws), the procedure of a roll called lower interlayer roll comprising the lower interlayer layer in a strip preferably which is based on PVB with at least 20% plasticizer, with a thickness Ei of at least 0.3 mm

[0364] 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 1H.

[0365] And even the coverage rate of the coating is preferably at most 25% or 10% when the extractor face is intended to be the rear face, extractor face possibly- actually in contact with the calender.

[0366] The coverage rate can be limited to promote cohesion of the laminate and lamination with the glass.

[0367] 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.

[0368] Depending 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.

[0369] In a second embodiment, the method of forming the roll (is roll to roll) and comprises (for the prints):

[0370] - (for the first print) the unwinding of a roll called the first unwinding roll interlayer comprising the first interlayer layer (31) in strip form, preferably which is based on PVB with at least 20% plasticizer

[0371] - (for the second draw separate from the first draw and associated with the third draw) 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 1H).

[0372] - said calendering of the bilayer and the first interlayer.

[0373] The method of forming a roll of laminate may comprise (upstream of the second draw, the formation of the insulating roll):

[0374] - the unwinding of a primitive roll comprising the first thermoplastic film in strip, in particular a rough print of said first thermoplastic film in strip form

[0375] - the liquid deposition of a composition called an insulating composition to form the optical isolating coating, preferably during said primitive drawing, in particular comprises a porous matrix (organic or mineral, in particular silica) and / or with hollow (nano)particles (in particular silica)

[0376] - a possible liquid deposition of a hard protective overcoat (in particular the dense matrix and / or without hollow nanoparticles)

[0377] - liquid deposition on the optical isolating coating (directly or on the overcoat) of a composition called an extracting composition comprising a matrix, in particular organic, crosslinkable (photo or thermocrosslinkable) and dif particles melting, 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

[0378] - a 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 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

[0379] The main known techniques for depositing a liquid composition are:

[0380] -by flow,

[0381] -by spraying (flow coating),

[0382] -by immersion (dip coating in English),

[0383] - by screen printing,

[0384] -by digital printing or inkjet.

[0385] In particular, a deposit can be made using 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.

[0386] 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 relative to the (external) contact surface of the turns. A controlled thickness of the liquid deposit is obtained.

[0387] In a roll (or roll-to-roll) process, it is preferred to deposit the insulating composition by flat die, by gravure roll, or with a Meyer bar.

[0388] The method of forming a roll of the laminate may comprise:

[0389] - unwinding a primary roll comprising said first thermo film plastic strip with, in particular, the optical insulating coating on the back, and possibly the lower interlayer (coating or sheet)

[0390] - or the extrusion of the lower interlayer, in particular in strip and in leaf,

[0391] - or the unwinding of a primary roll comprising the interlayer in lower strip, lower interlayer based on PVB with at most 5% plasticizer, thickness Ei of at most 80pm.

[0392] And it is followed by the deposition by liquid route 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 par particular, photo or thermo-crosslinkable) and diffusing particles layer in several patterns, to form the extraction layer.

[0393] 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.

[0394] 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.

[0395] The deposition of the extracting composition preferably takes place in a clean environment so as not to trap particles (during hardening).

[0396] Among the preferred techniques for depositing the extracting composition, we can cite: flexography, gravure printing, inkjet printing.

[0397] In the present invention, the light transmission TL (in %) and the haze (in %) are for example measured according to the ASTM D 1003 standard.

[0398] Other details and advantageous characteristics of the invention will appear on reading the examples according to the invention illustrated by the following figures.

[0399] [Fig.l] 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.

[0400] [Fig.l]' 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. [Fig.l]' describes steps in the manufacture of this illuminable laminated roof 100'.

[0401] [Fig.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. [Fig.2a] describes a step in the manufacture of this illuminable laminated roof 200.

[0402] [Fig.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.

[0403] [Fig. 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. [Fig. 3a] describes a step in the manufacture of this illuminable laminated roof 300.

[0404] [Fig.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.

[0405] [Fig.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. [Fig.4a] describes a step in the manufacture of this illuminable laminated roof 400.

[0406] [Fig. 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. [Fig. 5a] describes a manufacturing step of this illuminable laminated roof 500 and manufacturing alternatives in figures 5b, 5c, 5d, 5e.

[0407] [Fig.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. [Fig.6a] describes a step in the manufacture of this illuminable laminated roof 600.

[0408] [Fig.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.

[0409] [Fig.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.

[0410] [Fig.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.

[0411] [Fig.9a] represents a schematic view of a method of forming a roll used for manufacturing the functional laminate in a first configuration of the invention, roll-to-roll method.

[0412] [Fig.9b] represents a schematic view of a method of forming a roll used for manufacturing the functional laminate in a second configuration of the invention, roll-to-roll method.

[0413] [Fig. 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.

[0414] [Fig. 11] represents a schematic view of a method of forming the functional laminate roll in a third configuration of the invention, roll-to-roll method with in figures 10' and 10” variants of functional laminate according to the invention which can be obtained.

[0415] [Fig.l] represents a schematic sectional view of an illuminable laminated glass roof 100 of a motor vehicle according to the invention in a first embodiment. realization, with (in magnifying glass) a detailed view of the prismatic reflective film used to redirect the light and a detailed view of electroactive element 9 (optional).

[0416] In particular, for a fixed roof (canopy) the width is from 85cm to 1.4m and the length from 75cm to 1.65m.

[0417] This is a laminated car roof 100, (generally) rectangular and curved (in one or more directions), which comprises:

[0418] - a first sheet of glass 1, for example rectangular (of dimensions 1600X1100 mm for example with a thickness equal to 2.1 mm for example), with a first main face 11 corresponding to the face Fl a second main face 12 called face F2 and an edge (longitudinal slices 10 and 10'), the glass 1 being clear (Planiclear for example with 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 a light transmission or TL of approximately 28%)

[0419] - a second transparent sheet 2, preferably mineral glass, here the same shape and dimensions as the first sheet 1, forming internal glazing, 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 of TL of at least 91%, of thickness equal for example to 2.9 mm, glass 2 of refractive index ni of the order of 1.52 at 600nm or even Optiwhite glass of 1.95 mm or Sunmax glass of 2.05 mm.

[0420] - between the face F2 12 and the face F3 13, a transparent lamination interlayer 3, 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:

[0421] - 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)

[0422] - a second intermediate layer called lower 32, thermoplastic, preferably based on PVB (here with plasticizers, at least 20% or 30% by weight of plasticizers), clear (as transparent as possible and with as few optical defects as possible), for example 0.38mm, in adhesive contact with the F3 face, with a refractive index n3 of approximately 1.48 at 600nm, for example TL at 99.9%,

[0423] - a third interlayer called upper 33, thermoplastic, here of preferably based on plasticized PVB (at least 30% by weight plasticizers), for example of 0.38mm or 0.76mm (in one or two sheets), in adhesive contact with the F2 face, third clear interlayer or in a tinted variant, for example gray, of TL at 27%.

[0424] Alternatively, the lower interlayer 32 is based on PVB with little or no plasticizers (in particular less than 5% by weight of plasticizers), in particular MOWITAL film, for example with a thickness of at least 20 pm or 30 pm and at most 80 pm.

[0425] 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:

[0426] - the internal masking layer 7 is a black enamel on the F2 face

[0427] - 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 F2 face, ink preferably based on PVB with black pigments.

[0428] - the masking width at the front (front side edge) is for example 10 to 40cm

[0429] - the masking width at the rear (rear side edge) is for example 5 to 25cm

[0430] - the masking width on the long sides (longitudinal edges) is for example 5 to 20cm, identical or different width for the two long sides.

[0431] 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 <nl, de préférence sur la face arrière (orientée côte f3) d’un premier film transparent 5’, polymère et même thermoplastique (non adhésif au verre notamment, par exemple polyester, pet). alternativement couche isolateur optique est un fluoropolymère avec indice réfraction n2<nl.

[0432] 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.

[0433] 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 31' of the first interlayer 31.

[0434] 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 insulator layer 5.5' is in adhesive contact with the frame surface 31' and the face F3 13. The optical insulator layer (and even the first film 5') is here of a thickness less than 200 pm or even at most 100 pm and is protected at the periphery by the interlayer frame 34.

[0435] 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.

[0436] 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 Ipm, 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.

[0437] The first 5' film is transparent but can be tinted.

[0438] 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.

[0439] In one configuration, the optical isolating coating 5 comprises a matrix with a refractive index n2m greater than n2 and less than ni, and preferably with n2m of at most 1.48 (and n2 preferably of at most 1.42 and optionally at least 1.35), and comprising (nano)porosities and / or (nano)particles of low index (of refractive index less than ni), in particular hollow, of size preferably at most 300nm or even 100nm, for example hollow silica nanoparticles. The thickness of the optical isolating coating is preferably at most 100nm or 5pm and at least 800nm.

[0440] More broadly, the matrix can be a crosslinked or thermoplastic polymer, in particular chosen from 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.

[0441] Alternatively, the optical isolating coating 5 is porous silica.

[0442] In order to avoid folds, undulations, preferably the optical isolator layer 5.5' may be in an area of ​​the roof with a curvature, a sphericity limited in particular by a radius of curvature of at least 1.5m. For example, the edge of the first 5' film may be sufficiently far from the edge of sheets 1, 2. The masking width on the sides and / or front and rear may be adjusted (increased) for this purpose.

[0443] 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.

[0444] For the light function, the laminated glass roof 100 further comprises, masked from the outside by the internal masking layer 7:

[0445] - one or two groups of 4,4' light-emitting diodes (here with front emission or "top emission"), in the form of rectilinear strips 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

[0446] - third main face side F3, first and second redirection elements of light, peripherals, each forming an 8.8' reflective prismatic film comprising a main textured face with reflective prisms and an opposite main face called the smooth face.

[0447] For example, as shown in detail view, each reflective prismatic film 8 comprises a polymer prismatic film, for example 125 pm thick, with:

[0448] - a flat part or base 81 (substrate for example polyester, PET in particular of at least plus 100pm) in adhesive contact with the first interlayer 31 (with the frame surface 31')

[0449] - and a textured layer (embossing of a resin, for example crosslinked polyacrylate 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.

[0450] Here each reflective prismatic film 8 is in adhesive contact with the frame surface 31' (via the base 81) and with the front face of the intermediate frame 8. With this orientation of the films, the base 81 can be tinted, opaque to mask stray light.

[0451] 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).

[0452] The reflective prismatic films form, for example, two longitudinal strips on either side of the glass clear, opposite each 4.4' diode strip.

[0453] Alternatively, the prismatic film 81,82 is a monolithic polymer film, for example preformed example, coated with the reflective layer 83.

[0454] The light from the diodes 4, 4' is refracted in the second glass 2, in the reflective 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.

[0455] 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).

[0456] Alternatively, one or more transparent prismatic films are chosen on the face F4 side, downstream of the diodes. The diodes 4, 4' and / or their support may be secured to the face F4 (by an additional part, by direct gluing, etc.).

[0457] Alternatively, the diodes 4, 4' are side-emitting.

[0458] 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 (alternately or cumulatively) diode strips on the front or rear edges (on each side of the viewport).

[0459] The longitudinal edges 10, 10' here are not necessarily parallel.

[0460] The diffusing patterns 6 are for example extended or point geometric patterns.

[0461] 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.

[0462] For example, the diffusing coating is with an acrylate matrix, preferably with a refractive index greater than or equal to ni, with TiO2 particles of at least 100nm in diameter and preferably at most 1pm or 400nm. The diffusing coating is for example of a thickness of 100pm to 100pm or even 50pm.

[0463] The diffusing coating (for example matrix, such as a resin, with diffusing particles, such as TiO2, 100 to 200nm in diameter) can be deposited on the rear face of the PVB 32 facing the face F2 or on the optical isolating coating 5. For example, the diffusing coating (a diffusing pattern or network of patterns, disjoint and / or interconnected) in contact with the optical isolating coating preferably covers at most 50% or 40% of the clear glass to promote adhesion of the optical isolating coating with the lower interlayer 32.

[0464] 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.

[0465] You can choose diodes emitting white or colored light for ambient lighting, reading lighting, etc.

[0466] Several series of diodes 4 (one edge, two edges, three edges, over the entire periphery) can be provided, controlled independently and even of different colors.

[0467] An infrared-reflecting coating 17 on face F4 forms a low-emissivity layer (in particular an ITO multilayer, in particular Ito between two layers of oxide and / or metal nitride and / or Si).

[0468] The roof 100 comprises between the upper interlayer 33 and the first interlayer 31, an electroactive (electro-optical) device 9, here with variable diffusion, in particular based on liquid crystals. The device 9 is even in adhesive contact with the upper interlayer 33 and the interlayer 31.

[0469] 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.

[0470] For example, the blur in the diffusing state of the roof with the variable diffusion device 9 is at least 80%.

[0471] As shown in the detailed view, the variable diffusion device 9 comprises:

[0472] -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 face F2 side

[0473] -an electroactive layer 93, which is based on liquid crystals in a polymer matrix (for example PDLC in English),

[0474] - a second support 91' (polymer, thermoplastic PET of 125pm for example) with a second electroconductive coating 92' (for example ITO) 92' on the third face F3:

[0475] 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, 91' are protruding on two opposite sides.

[0476] 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.

[0477] Alternatively, the device 9 is replaced by another electroactive device, for example electrochromic or even a functional PET film (tinted, etc.).

[0478] 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 intercalary layer 33.

[0479] The lower block and upper block assembly is designated by the name of complete block which is in adhesive contact with the glasses 1,2 (bare or custom-coated).

[0480] 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 trilayer 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 trilayer preferably carrying the light extraction layer 6 in one or more diffusing patterns, for example disjointed.

[0481] Figures 1a and 1b describe the main steps of manufacturing the illuminated laminated roof 100 from such a roll of laminated laminate.

[0482] [Fig. 1a] illustrates in top view the main stages of roof manufacturing 100 illuminated laminated paper with various cutting operations and local joining.

[0483] The first step 201 illustrates in a roll-to-roll process:

[0484] - a continuous drawing of the laminated strip using guide rollers 1000 and 1000' along an X axis (horizontal),

[0485] - 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

[0486] - a lateral rectilinear cut (along Y) of the winding roller 1001 in particular when the strip length reaches at most 300 or 200m to facilitate handling and maintain winding quality.

[0487] When the (each) excess peripheral strip is wide, it is wound onto another separate roll.

[0488] It is possible to plan to shift the blade in Y (perpendicular to X, in a horizontal plane) during the drawing, for a complex cut, for example oblique, and preferably still rectilinear (rather than curved).

[0489] The second step 202 illustrates the following operations:

[0490] - unwinding of roll 1001, with drawing of the functional three-layer laminate in band,

[0491] - lateral rectilinear cutting along Y by blade 192 (controlled) to a length desired (predetermined) functional three-layer laminate.

[0492] The third step 203 comprises (on an assembly table):

[0493] - with a blade 193, a circumferential and partial cutting 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 31' projecting from the first interlayer 31, preferably with a width W1 of at least 20mm (and preferably at most 200mm or 100mm), called the whole layer.

[0494] The fourth step 204 comprises (on an assembly table):

[0495] - the formation of the intermediate lamination frame 34 of thickness Ec preferably of at least 0.3mm (and in usual PVB) to be more easily handled without folds, of width Wc preferably of at least 20mm (and even less than or equal to Wl), preferably from an interlayer, in sheet form, (rectangular or other shape compatible with the desired dimensions and shape), by cutting with a blade 194.

[0496] Preferably, an automatic cutting system is used, itself composed of a mounting table, possibly a belt, the blade supported in an orientable tool which is itself integral with a horizontal movement system (in XY, preferably horizontal plane) of the carriage type mounted on a bridge.

[0497] 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.

[0498] Preferably, to press the element to be cut, there is suction by means of orifices in the belt.

[0499] Of course, we can have a duplication of means, that is to say another blade supported in an adjustable tool.

[0500] Steps 203 and 204 are concomitant or consecutive or at different times (storage of the intermediate frame, the pre-cut laminate, etc.).

[0501] The fifth step 205 comprises the formation of the manipulable lower block 110 comprising the three-layer and, secured by local connections of the three-layer, the intermediate frame 34 and the two prismatic reflective films 8,8' along opposite edges, here longitudinal edges of the three-layer (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).

[0502] The local connections (adhesive contacts) are in particular point 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).

[0503] The temperature and pressure are adjusted according to the interlayer material and the tool, in particular heating fingers or soldering iron.

[0504] 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.

[0505] With heating fingers (melting of all or part of the thickness of interlayer material, PVB), the temperature can be around 100°C and pressure is applied.

[0506] The local connections, in particular for the heating fingers, are preferably 8 to 15 mm long and spaced 20 cm to 30 cm apart.

[0507] For the intercalary frame 34 / tri-layer bonding, the contact zones for the local connections can be centered a few mm from the boundary 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 boundary.

[0508] Several local connections are made (distributed regularly or not) around the entire perimeter of the intermediate frame 34 / lower intermediate layer 32.

[0509] The intercalary frame 34 / tri-layer bonding can be done in one operation for all the local connections. A heating tool can be chosen which allows the various point adhesive points to be made in a single operation, for example via the heating fingers.

[0510] 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 shown schematically by circles in [Fig.1a].

[0511] There is cast iron between the intermediate frame 34 and the lower intermediate layer 32 and also between frame and first interlayer 31.

[0512] The 8,8' prismatic films are secured by local bonds with at least the first interlayer 31 and the interlayer frame 34, by (local) softening of interlayer material, by local heating (with heating fingers etc.).

[0513] The sixth step 206 comprises an assembly step comprising:

[0514] - a placement (and centering) on ​​the second glass sheet 2 called sheet of reference of the complete block 120 (lower block 110 secured to the upper block 111 as detailed in sectional view later in [Fig.lb])

[0515] - a possible local solidarity complete block 120 / second sheet 2, by local heating as mentioned above (multiple welding points) of the interlayer material (adhesive contact)

[0516] - a positioning of the first sheet 1, carrying the masking frame 7 on the complete block 120

[0517] - possible local bonding of complete block 120 / first sheet 1, by heating local as mentioned above (multiple welding points), of the interlayer material (adhesive contact)

[0518] - the lamination.

[0519] The lamination preferably comprises:

[0520] - a vacuum (to evacuate the air present between the two sheets of glass, by suction etc, “cold”, at room temperature) for a period of 15 to 45 min,

[0521] - 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).

[0522] After lamination, the first film 5, the reflective prismatic films 8', 8 are protected, encapsulated by lamination interlayer material (here PVB) by finishing (of the first interlayer sheet 31 etc.).

[0523] In particular in a first configuration for managing the interlayer edges: - 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 - the process includes trimming the complete block 120 before degassing (i.e. cutting to be edge to edge with the glasses 1,2) - after autoclave, the process includes brushing (removal) of excess PVB from the edge of the roof.

[0524] 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 frame in intercalary 34 and of the other frame 35 and of the intercalary 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'.

[0525] [Fig. 1b] illustrates in sectional view the main stages of manufacturing the self-laminated roof 100 with various cutting operations and local joining.

[0526] The first step 101 (corresponding to step 203 already described in top view in [Fig.1a]) is the circumferential and partial cutting leaving the frame surface 31' protruding and a cut-out part comprising the elements 32, 5, 5'.

[0527] The second placement step 102 includes:

[0528] - placement of the reflective prismatic films 8.8' on the frame surface 31' and along the longitudinal edges of the cut-out part of the three-layer, ensuring that the reflective prismatic films 8.8' 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).

[0529] 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.

[0530] The third step 103 of solidarity includes: - 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.).

[0531] 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:

[0532] - a placement of the intermediate frame 34 on the frame surface 31'

[0533] - a local connection 195 of the intermediate frame 34 to the frame surface 31', by example in multipoints, by local softening of the intermediate frame 34 and the frame surface 31' (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 overhang or withdrawal of at most 1mm) and spaced at most 1mm or against the cut part of the three-layer; for example, a multipoint weld is made in one operation.

[0534] In the first variant, the formation of the lower block 110 comprises in this order:

[0535] - placement of the reflective prismatic films 8,8' (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'

[0536] -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 heated fingers as mentioned above etc), for example multi-point welding in one operation.

[0537] In a second variant, the formation of the lower block 110 comprises in this order:

[0538] - a placement of the reflective prismatic films 8, 8' on the intermediate frame 34 (at less than 4mm and better 1mm from the edge of the first film 5 or even attached),

[0539] - a local pre-solidarization of the 8.8' reflective prismatic films on the frame in intercalary 34 (front face of the intercalary frame 34) by local softening of the frame (local heating, by heating fingers as mentioned above, etc.),

[0540] - a placement of the intermediate frame 34 secured to the prismatic reflective films 8.8' on the frame surface 31',

[0541] - a local joining of the reflective prismatic films linked to the frame in intercalaire 34 with the three-layer by local softening (local heating, by heating fingers, etc.), for example multi-point welding in one operation.

[0542] 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:

[0543] - a placement of the other intermediate frame 35 on the upper intermediate layer 33,

[0544] - if peripheral protection is necessary: ​​placement of the first protection frame in Z 94 (in three sections 941, 942 and 943) on the internal periphery of the other intermediate frame 35, and a joining of the first protective frame in Z 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 (over the entire periphery) in one operation

[0545] - a placement of the electroactive element 9 for example based on liquid crystals (PDLC etc) within the other intermediate framework 35

[0546] - if peripheral protection is necessary: ​​placement of the second frame of protection 944 (of rectangular section) on the other intermediate frame 35 (and on the periphery of the electroactive element 9), a joining of the second protection 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 (over the entire perimeter) in one operation.

[0547] 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.

[0548] The shape of the protective frames (C, Z etc) can be done by folding etc. A protective material can also be used (by liquid deposition etc).

[0549] In another variant, the electroactive element 9 comprises an internal peripheral protection, possibly an internal polymer seal between the two electro-active films. ductors 91.91' (on the perimeter of element 93).

[0550] This step 104' can be carried out before, during, or in parallel with step 104.

[0551] As a variant of this step 104', the third interlayer 33, called upper (PVB sheet), the electroactive element 9 before the other intermediate frame 35

[0552] -so we place the second protection frame 944, the element 9 before the Z protection frame 941,942,943 and the other intermediate frame 35

[0553] - or we place element 9 with already a peripheral protection (in C) then the other 35 spacer frame.

[0554] The fifth step 105 of forming the complete block 120 (ready for assembly) comprises:

[0555] - a placement of the lower block 110 on the upper block 111 composed of the element 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,

[0556] - (not shown) a local joining of the first interlayer 31 with the other intermediate 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.

[0557] 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).

[0558] Once the complete block 120 has been completed, it can be turned over (rotated 180°), especially if the second sheet 2 is chosen as the reference sheet.

[0559] The sixth assembly step 106 for lamination comprises:

[0560] - a placement (with centering) on ​​the second glass sheet 2 called sheet of reference 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

[0561] - a possible local bonding of the lower block / second sheet 2, by ramol smoothing of the interlayer material (local heating, multi-point welding, etc.)

[0562] - a positioning of the first sheet 1, carrying the masking frame 7 on the block set 120

[0563] - possible local solidarity upper block or even complete / first sheet 1 (local heating, multi-point welding, etc.)

[0564] The lamination is then carried out.

[0565] All steps 101 to 106 are in a clean atmosphere, particularly in the room white.

[0566] Glass sheets 1,2 are clean.

[0567] 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.

[0568] [Fig.l]' 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.

[0569] It differs in that the reflecting prisms 8, 8' are within the intermediate frame 34 with double PVB sheets, 341, 342 (still part of the lower block 110'). The electroactive element 9 is here more extensive than the first film 5'. The opposite is also possible.

[0570] 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).

[0571] The manufacture of the complete block 120' is quite similar to that described for the complete block 120 of [Fig.l]. Only the differences are detailed in relation to [Fig.l]'a illustrating in sectional view the stages of manufacture of the illuminable laminated roof 100'.

[0572] After the first partial cutting step is as already described previously, the second step 102 comprises:

[0573] - a pre-solidarization 195 of the reflector prisms 8, 8' with the two frame sheets of upper 341 and lower 342 PVB (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)

[0574] - a placement of the multi-sheet frame 34 with the reflector prisms 8, 8' on the frame surface 31'.

[0575] 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 the perimeter, in one operation etc.).

[0576] 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.

[0577] Alternatively, the prismatic film(s) have prisms 82, 83 oriented towards the face F2.

[0578] Alternatively, a possible transparent overlayer (protective, etc.) is inserted between the optical isolating coating 5 and the extraction layer 6.

[0579] [Fig.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.

[0580] It differs from the first mode 100 in that:

[0581] -the reflecting prisms 82, 83 of the reflecting prismatic films 8, 8' are oriented towards face F2 12, within the lower block 210, with the smooth face against or glued to face f3 13

[0582] - possibly an overlayer 51 (protective etc.), transparent, is interposed between the optical isolating coating 5 and the extraction layer 6.

[0583] 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 [Fig.1a], certain manufacturing steps are detailed in relation to [Fig.2a].

[0584] After the first step of circumferential cutting and partial cutting as already described, a second step 102, of placement, comprises:

[0585] - a placement of the intermediate frame 34 on the frame surface 31',

[0586] - a placement of the reflecting prismatic films 8, 8' (reflecting prisms 82, 83 oriented towards the intermediate frame 34) on the rear face of the intermediate frame 34.

[0587] This is followed by a third step 103 of solidarity comprising:

[0588] - a connection 195 of the intermediate frame 34 with the first intermediate layer 31 and even of the lower interlayer 32 by local softening of interlayer material - interlayer frame 34; first interlayer 31, lower interlayer 32 - (local heating, with heating fingers for example, on multiple contact zones.) and a joining 195 of the reflector prisms with the interlayer frame 34, by local softening of the interlayer frame 34 (local heating, with heating fingers for example, on multiple contact zones.).

[0589] Alternatively, the second step 102 comprises:

[0590] - a placement of the intermediate frame 34 on the frame surface 31',

[0591] - a connection 195 of the intermediate frame 34 with the first intermediate layer 31.

[0592] And a third step 103 comprises:

[0593] - a placement of the reflective prismatic films 8, 8' (prisms 82,83 towards the frame spacer 34) on the front face of the spacer frame 34

[0594] - a connection 195 of the reflecting prisms with the intermediate frame 34, by ra 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.

[0595] 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.

[0596] [Fig.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.

[0597] It differs from the roof of the second mode 200 in that:

[0598] -films 8, 8' are transparent prismatic films (monolithic or with base covered with a textured layer, for example resin, embossed etc.), without a reflective layer, spaced or secured to 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)

[0599] - optionally the lower interlayer 32' is a PVB without plasticizer (or with less than 10% or 5% plasticizer) for example 30pm or 50pm thick - and carrier here on the rear face of the light extraction layer in one or more diffusing patterns 6 (or alternatively on the front face),

[0600] - possibly the absence of layer 17

[0601] Alternatively the light extraction layer is on the F3 or F4 side, for example diffusing resin or diffusing enamel.

[0602] An optical element (prism etc.) can be inserted between the diodes and the films and / or side-emitting diodes can be chosen.

[0603] The manufacture of the complete block 221 (upper block 111 on lower block 211) comprises:

[0604] - the circumferential and partial cut leaving the frame surface 31' protruding and a cut part 32.5.5',

[0605] - the placement of the intermediate frame 34 on the protruding frame surface 31', then solid- local darization, by softening of interlayer material, of PVB (local heating, in particular by heating fingers),

[0606] - then the placement of the lower block 211 on the upper block 111, then joining local by softening of interlayer material, of PVB (local heating, in particular by heating fingers) - as already described in the fifth step 105-.

[0607] The next step of placing the complete block 221 for lamination is for example identical to step 106 already described.

[0608] 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.

[0609] Alternatively, the upper block is removed.

[0610] We can add the already mentioned layer 17 and / or delete layer 18 and use a first tinted glass (and a tinted or clear upper interlayer 33).

[0611] The top block is optional.

[0612] [Fig.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.

[0613] The roof 300 differs from that of the second mode 200 in that:

[0614] - the optical isolator layer is formed by a 5” fluoropolymer film (corona treated) thickness for example 50pm,

[0615] - optionally the lower interlayer 32' is a PVB without plasticizer (or with less than 10% or 5% plasticizer) for example 30pm or 50pm thick - and carrier here on the rear face of the light extraction layer in one or more diffusing patterns 6 (or alternatively on the front face),

[0616] - by the absence of an intercalary frame around the trilayer because E' is less than 200pm and even at most 150pm or 100pm.

[0617] The manufacture of the lower block 310 is partly described by [Fig.3a]:

[0618] - 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 frame surface 31' protruding and a cut portion 32',5”,

[0619] - the second step 102 is the placement of the reflecting 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)

[0620] - 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'

[0621] The next step (not shown) of forming the complete block 320 (ready for assembly) comprises:

[0622] - a placement of the placement of the lower block 310 on the upper block 111 already described, therefore front face of the first intercalary layer 31 on electroactive element 9 and on the other intercalary frame 35

[0623] - a local joining of the first interlayer 31 with the other frame in intercalaire 35 (local heating, with heating fingers, multi-point welding).

[0624] The next step of placing the complete block 320 for lamination is for example identical to step 106 already described.

[0625] [Fig.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.

[0626] It differs from the roof of the third mode 300: - 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), - 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 - possibly a single prismatic reflector film 8 (and a single diode strip 4) for example on a longitudinal edge or on a lateral edge (front or rear).

[0627] The manufacturing steps of block 311 are identical to those described for the lower block 310 of [Fig.3].

[0628] The next assembly step for lamination includes:

[0629] - a placement (centering) on ​​the second glass sheet 2 called sheet of block reference 311, brought into contact with face F3 13

[0630] - a possible local joining of the first interlayer 31 with the second sheet 2, by softening of the first interlayer (local heating, multi-point welding)

[0631] - a positioning (centering) of the first sheet 1, carrying the frame of masking 7 and layer 18 (optional) on block 311

[0632] - a possible local joining of the first interlayer 31 with the first sheet 1 (local heating, multi-point welding).

[0633] The lamination is then carried out.

[0634] As a variant, the electroactive element 9 is 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 intercalary frame 35 so that the laminated laminate also comprises, in addition to the three-layer (and before the partial cutting of the laminate 101) - the third intercalary layer 33 - the electroactive element 9, set back from the edges of the third interlayer 33 and the first interlayer 31, encapsulated, protected by these sheets.

[0635] [Fig.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.

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

[0637] - the reflecting prisms 82, 83 of the prismatic films 8, 8' are oriented towards the face F2 12 and bonded to the rear face of the lower interlayer 32, at the edge, still under the masking frame 7, and against or glued to the face F3 13

[0638] - two opaque bands 7' (coating, black for example, on the first film of preferably on the back) are opposite the prismatic films 8, 8' in the event of stray light (passing through the prismatic films 8, 8')

[0639] - 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 50pm to 200pm) 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 solar control function.

[0640] The electroconductive coating thus removed from the bare F2 face or which can have another functional coating), we can also have a composite functional film without an electroconductive coating

[0641] The laminate 420 is a laminated multilayer which comprises, in addition to the trilayer 32, 5' (with its coating 5), 31, - and the interlayer frame 34 on the periphery of the trilayer - 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').

[0642] 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.

[0643] Concerning the manufacture of the roof 400 illustrated in part in [Fig.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).

[0644] A second step 102 follows, comprising:

[0645] - 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 bands 7')

[0646] This is followed by a third step 103 comprising:

[0647] - a joining 195 of the reflecting prismatic films 8, 8' by softening local heating of the lower interlayer 32 (local heating, with heating fingers for example on two contact zones, in one operation)

[0648] - a placement of the intermediate frame 34 on the frame surface 31',

[0649] - a joining of the intermediate frame 34 by local softening of the layer in lower intercalary 32 and the intermediate frame 34 (local heating, with heating fingers for example all around in one operation).

[0650] 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.

[0651] It is also possible to place the intermediate frame 34 and the reflective prismatic films 8, 8' and to make a connection between the intermediate frame 34 and the reflective prismatic films 8, 8' in a local heating operation.

[0652] [Fig. 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.

[0653] It differs from the roof of the first mode 100 in that:

[0654] - the lower interlayer 32 is whole

[0655] - the first interlayer 31 is shorter than the interlayer in lower 32 (set back from layer 31)

[0656] 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.

[0657] The intercalary frame 34 is on the periphery of the first intercalary layer 31 (and of the first film 5 with its coating 5' or of a fluoropolymer in varainte).

[0658] The reflective prism films 8, 8' are between the rear face of the interlayer frame 34 and the front face of the lower interlayer layer 32.

[0659] The manufacture of the lower block 510, of the complete block 520 is described in relation to [Fig.5a].

[0660] 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 portion 31,5,5' of the three-layer.

[0661] The second placement step 102 includes:

[0662] - a 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 4mm and better 1mm from the edge of the first film 5 or even attached).

[0663] The third step 103 of solidarity includes: - 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,) - the placement of the intermediate frame 34 on the prismatic reflective films 8.8' and the frame surface 321.

[0664] The fourth step 104 of solidarity includes: - a local bonding 195 of the intermediate frame 34 to the frame surface 321 by local softening of the frame surface 320 (for example over the entire

[0665]

[0666]

[0667]

[0668]

[0669]

[0670]

[0671]

[0672]

[0673]

[0674]

[0675] around, by local heating, by multiple welding points, by heating fingers). The fifth step 105 of forming the complete block 520 includes: - 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) - 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. 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. 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. In another configuration (see [Fig.5b]) the fifth step 105 of forming the complete block 520 (ready for assembly) comprises: - 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) - (not shown) a local connection of the intermediate frame 34 with the other intermediate frame 35. (local heating, with heating fingers, multi-point welding) Alternatively, the lower block 510' comprises: - a 5” fluoropolymer film (corona treated) instead of the first 5' film with the low index 5 coating - 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 - and / or one or more reflecting prisms 8, 8' in a multi-sheet frame 341,342 for example on two opposite edges. 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). As shown in [Fig.5c], the formation of this lower block 510' includes in this order (after partial cutting of the trilayer): - 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)

[0676] -a second step 102 of placing the multi-sheet frame 34 with the reflector prisms 8, 8' on the frame surface 321,

[0677] - a third step 103 comprising the securing of the multi-sheet frame 34 to prisms on 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).

[0678] Carrying out the partial cutting on the first interlayer 31 possibly makes it possible to use a single thick interlayer frame 34' (single or multi-layer) to protect both the electroactive element 9 and the optical isolator layer 5 having similar dimensions and therefore to reduce the operations.

[0679] As shown in [Fig.5d], the fifth step 105 of forming the complete block 520 then comprises:

[0680] - successive placement:

[0681] -of the thick frame 34' on the surface 321 (with already the prismatic films 8,8' possibly),

[0682] - protective film 94 in Z on the first interlayer 31

[0683] - of the electroactive element 9 on 94 and on the first interlayer 31

[0684] - of the protective film 944 on element 9 and on 94 and interlayer frame 34'

[0685] - of the third interlayer 33 (wider than 9) - 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.

[0686] It is possible to alternatively place and secure the intercalary frame 34' with the lower intercalary layer 32, place the protective film in Z 94, place element 9, and secure it with the intercalary frame 34 and films 94 and 944, place the third intercalary layer 33 and secure it with the intercalary frame 34' (local heating).

[0687] It is possible to alternatively place and secure the intercalary frame 34' already carrying the prismatic films (on the surface or in a multi-sheet) with the lower intercalary layer 32, place the protective film in Z 94, place element 9, secure the films 94 and 944 with the intercalary frame 34, place the third intercalary layer 33 and secure with the intercalary frame 34'.

[0688] 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.

[0689] As shown in [Fig.5e], the fifth step 105 of forming the complete block 520 then comprises:

[0690] - successive placement:

[0691] - 8.8' reflective prismatic films on the frame surface 321, prismatic films reflectors 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)

[0692] -of the thick frame 34', on the reflective prismatic films 8,8' and the frame surface 321

[0693] -of the protected electroactive element 9,

[0694] -of the third interlayer 33 on the element 9 and the frame 34' - 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).

[0695] It is possible to alternatively place and secure the intercalary frame 34' already carrying the prismatic films (on the surface or in a multi-sheet) with 32, place element 9, place the third intercalary layer 33 and secure it with the intercalary frame 34'.

[0696] [Fig.6] represents a schematic sectional view of a laminated glass roof illuminable 600 of a motor vehicle according to the invention in a sixth embodiment.

[0697] It differs from the roof of the first mode 100:

[0698] -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)

[0699] - by the absence of an interposed frame around the perimeter 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.

[0700] The manufacture of the lower block 610 is described in part in relation to [Fig.6a]: - first step 101: possible: marginal cutting of the interlayers 31, 32 (to the dimension of glasses 1, 2 and even depending on the shape of the glasses), the optical isolator layer being integral

[0701] - second step 102: placement of the prismatic films 8, 8' on the rear face of the lower interlayer 32

[0702] - third step 103: joining 195 of the prismatic films 8, 8' with the layer lower spacer 32 (by local heating).

[0703] This results (not shown) in the formation of the complete block 620:

[0704] - placement of the lower block 610 (turned over, by rotation 180°) on the upper block 111 as already described,

[0705] - (not shown) joining by local heating of the blocks by softening of the first interlayer 31 and the other interlayer frame 35, of the in- lower intercalary 32.

[0706] The next assembly step for lamination includes:

[0707] - a placement (centering) on ​​the second glass sheet 2 called sheet of complete block reference 620

[0708] - a possible local solidarity complete block / second sheet 2, by ramol smoothing (local heating) of the first interlayer 31, of the other interlayer frame 35, of the lower interlayer 32 (multiple welding points)

[0709] - a positioning of the first sheet 1, carrying the masking frame 7 on the complete block 620

[0710] - a possible local solidarity third intercalary layer 33 / first sheet 1 (local heating, multi-point welding)

[0711] The lamination is then carried out.

[0712] As a variant, the electroactive element 9 is for example laminated by calendering, for example an all-solid electrochrome, with a thickness of at most 200 μm, without the need for another intercalary frame 35 so that the laminated laminate also comprises in addition to the three-layer (and before the possible marginal cutting)

[0713] [Fig.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.

[0714] It differs from the first mode 100 in that:

[0715] - the reflecting prisms 82, 83 of the films 8, 8' are oriented towards the face F2 12, within from lower block 210

[0716] - the sheets 31, 5, 32 are edge to edge so that the intermediate frame 34 (clear or tinted) is in contact with the other interlayer frame (clear or tinted) 35.

[0717] The electroactive element 9 is here the same size as the first interlayer 1. However, it can be larger or smaller indifferently.

[0718] Figures 7a to 7b describe the main steps in manufacturing the illuminable laminated roof 700.

[0719] [Fig.7a] illustrates in top view the main stages of manufacturing the illuminated laminated roof 100 with various cutting operations and local joining.

[0720] The third step 203 comprises:

[0721] - a circumferential and total cut, of the first intercalary layer 31, of the first film 5 and the lower interlayer 32.

[0722] The fourth step 204 includes:

[0723] - the formation of the intermediate lamination frame 34 of thickness Ec preferably of at least 0.3mm to be more easily handled without folds etc., of width Wc preferably of at least 20mm (and less than or equal to Wl), preferably from of an interlayer (rectangular sheet etc.) by cutting with a 194 blade (on a mounting table).

[0724] Steps 203 and 204 are concomitant or consecutive or at different times (storage of the frame, of the pre-cut laminate, etc.).

[0725] The fifth step 205 comprises the formation of the manipulable lower block 710 comprising the trilayer and, secured by local connections to the trilayer, the intermediate frame 34 and the two reflective prismatic films 8,8' along opposite edges, here longitudinal edges of the trilayer (quadrilateral). The two reflective prismatic films 8,8' are adjacent to the trilayer.

[0726] The bonds are in particular spot welds 195, by (local) softening of interlayer material (of the frame and / or of the three-layer). The bonding is by local heating and possibly also by pressure. This bonding is preferred to bonding by bead of glue or double-sided adhesive.

[0727] The temperature and pressure are adjusted according to the interlayer material and the tool, in particular heating fingers or soldering iron.

[0728] of intercalary material), the temperature is approximately 100°C and pressure is applied

[0729] For the intercalary frame 34 / trilayer bonding, the contact zones for the local connections can be centered a few mm from the boundary between intercalary frame 34 and trilayer (which is a junction or an interlayer space of at most 1 mm) and on either side of the boundary.

[0730] Several local connections are made around the entire perimeter of the intermediate frame 34 / lower intermediate layer 32.

[0731] The intercalary frame 34 / tri-layer bonding can be done in one operation for all the local connections. A heating tool can be chosen which allows the various point adhesive points to be made in a single operation, for example via the heating fingers.

[0732] 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 [Fig.7a],

[0733] ​​Similarly, the prismatic films are secured by local connections with the intercalary frame 34, by (local) softening of the intercalary material, by local heating (with heating fingers, etc.).

[0734] The sixth step 206 comprises an assembly step comprising:

[0735] - a placement on the second glass sheet 2 called the reference sheet of the block complete 720 (lower block 110 attached to the upper block 111 as detailed in view cutting subsequently in [Fig.7b])

[0736] - possible local bonding (local heating) lower interlayer 32 / second sheet 2

[0737] - a positioning of the first sheet 1, carrying the masking frame 7 on the complete block 120

[0738] - possible local bonding (local heating), third interlayer 33 / first sheet 1.

[0739] The lamination then includes:

[0740] - 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 min,

[0741] - 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).

[0742] After lamination, the first film 5, the reflective prismatic films 8', 8 are protected, encapsulated by lamination interlayer material (PVB here).

[0743] [Fig.7b] illustrates in sectional view the main stages of manufacturing the car roof laminated 700 with various cutting operations and local joining.

[0744] The first step 101 is a total cutting of the laminate 31, 5, 5', 32 preferably by a blade 193.

[0745] The second step 102 comprises:

[0746] - a placement of the intermediate frame 34 on the electroactive element 9 (with films of protection 94,944) and on the other frame 35 of the upper block 111

[0747] - a 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)

[0748] - a local pre-solidarization 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.),

[0749] - the placement of the cut three-layer in the frame 34 (and a possible solida local heating (local heating) three-layer cut / frame 34.

[0750] An alternative for manufacturing the roof 700 is shown in [Fig.7c] in particular if the lower block is removed.

[0751] The first step 101 remains a total cutting of the laminate preferably by a blade 193.

[0752] The second step 102 comprises:

[0753] - a placement of the 8.8' prismatic reflective films on the F3 face of the second glass sheet 2, prisms oriented opposite the face F3

[0754] - a placement of the intermediate frame 34 on the prismatic reflective films 8.8' 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)

[0755] - a local pre-solidarization 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.),

[0756] - placement of the cut-out three-layer in the frame 34

[0757] - local joining of the three-layer with the frame 34 (local heating, by fingers heaters etc.),

[0758] This is followed by the placement of the first sheet of glass 1 and then the lamination.

[0759] An alternative for manufacturing the roof 700 is shown in [Fig.7d] in particular if the lower block is removed.

[0760] - on face F2 of the first sheet 1, placement of the frame 34 then of the three-layer cut out within framework 34, local solidarity

[0761] - a placement of the reflective prismatic 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)

[0762] - a local attachment of the reflective prismatic films 8, 8' on the frame (face front of the intermediate frame 34) by local softening of the frame (local heating, by heating fingers etc.),

[0763] This is followed by the placement of the second sheet of glass 2 and then the lamination.

[0764] Or we can also provide:

[0765] - on face F2 of the first sheet 1, placement of frame 34 with the films taken matic 8.8' pre-bonded reflectors (by local heating, by heating fingers etc.) then the three-layer cut within the frame 34, and local bonding.

[0766] This is followed by the placement of the second sheet of glass 2 and then the lamination.

[0767] An alternative for manufacturing the roof 700 is shown in [Fig.7e] in particular if the lower block is removed.

[0768] - on face F2 of the first sheet 1, placement of the frame 34 multi-sheet 341,342 housing the pre-bonded 8.8' prismatic reflective films then the three-layer cut within the frame 34, local bonding.

[0769] This is followed by the placement of the second sheet of glass 2 and then the lamination.

[0770] An alternative manufacturing of the roof 700 is shown in [Fig.7f] in which there is a common intercalary frame 34' (PVB) for the laminate and the electroactive element 9.

[0771] A step 102 (after complete cutting of the three-layer) is the placement on the rear face of the lower interlayer 32 of the prismatic reflective films 8, 8' and their joining by local connections (local heating).

[0772] A next step 103 is on the third interleaf sheet 33 the placement of the common frame 34' thick, then in the common frame 34' placement of the electronic element 9' already protected e.g. C 94 film, three-layer laminate with 8, 8' reflective prismatic films.

[0773] [Fig.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.

[0774] It differs from mode 700 in that the reflecting prisms 82, 83 of the films 8, 8' are on the rear face 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.

[0775] The manufacture of the complete block 720' is quite similar to that described for the complete block 720 of [Fig.l].

[0776] It is preferred that the prismatic films are not in the laminate laminated by calendering machine but added after calendering, because there is a risk of damaging them.

[0777] [Fig.8] represents 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.

[0778] The method of forming the functional laminate roll 1001 comprises:

[0779] - from the unwinding of a roll called the first interlayer unwinding roll 2002 comprising the first interlayer (sheet) 31 in 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 print of the first interlayer (sheet) 31, 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,

[0780] - 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 draw of the two-layer, in strip, preferably with a guide roller 2011

[0781] - heating of the first interlayer 31 in strip form, by means of re IR 1111 resistors close to the band

[0782] - 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

[0783] - possibly after calendering one or more guide rollers 1000 and even cooling dissement

[0784] - if necessary the insertion of a temporary protective polymer film 36 (anti adhesive) for example polyethylene (PE)-, strip unwound 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,

[0785] — winding the laminated laminate onto the so-called winding roller 1001.

[0786] A total cut along the edges of the strip laminate 212 and / or a cut lateral 190 can intervene.

[0787] To make the unwinding more reliable, swelling mandrels can be used.

[0788] The rollers of the calender can be metallic, polymer (rubber) or one metal, the other polymer (rubber).

[0789] The rear face of the first interlayer 31 intended to be in adhesive contact with the first film 5 (the coating 5) after lamination is preferably smooth. The front face may be smooth or rough, in particular if in adhesive contact with the face F2.

[0790] The rear face of the lower interlayer 32' coated with the diffusing coating is smooth.

[0791] The diffusing coating 6 may be a hard coating with sufficient hardness (at least 1H) 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%.

[0792] 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 insulating 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.).

[0793] We can also do in variants:

[0794] -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 liquid-deposited diffusing coating on the back face or on the optical isolator coating 5 (possibly protected)

[0795] - a strip laminate 213 (see [Fig.8]') with the diffusing coating between a first film which is 5” fluoropolymer, notably corona treated (for example 50pm FEP), from roll 2001, and the back face of the lower interlayer 32' (preferably liquid-diffusing coating on the front face of the 32' layer or alternatively on the back face)

[0796] - a strip laminate 214 (see [Fig.8]”) with the diffusing coating 6 between the re optical isolating garment 5 (possibly protected) and the rear face of the lower interlayer 32 which is preferably made of standard plasticized PVB of at least 0.3 mm (preferably a diffusing coating by liquid deposition on the optical isolating coating 5).

[0797] [Fig.9a] represents a schematic view of a method of forming a roll used for manufacturing the functional laminate, in a first configuration, roll-to-roll method.

[0798] This process includes:

[0799] - from the unwinding of a primitive roll 3001 comprising the first thermal film 5' thermoplastic film 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 roller 3011

[0800] - liquid deposition here for example by printing via ink roller 3002 on the optical isolating 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 primitive drawing

[0801] - a winding of the first film with the optical isolating coating and the layer 6 light extraction in a 2001 winding roller.

[0802] The roll can be unrolled as is for the second print (used in a mode related to the following [Fig. 10]) the lower interlayer 32 is added (used in a mode related to the previous [Fig.8]” for example).

[0803] Alternatively:

[0804] - from the unwinding of a primitive roll 3001 comprising the first thermal film thermoplastic 5 in strip, a primitive drawing of said first thermoplastic film in strip, preferably with a guide roller 3011

[0805] - the liquid deposition of a composition called an insulating composition to form the optical isolating coating, during said original drawing,

[0806] - liquid deposition here for example by printing via ink roller 3002 on the optical isolating 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 print or in resumption during a subsequent print

[0807] - a 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.

[0808] [Fig.9b] represents a schematic view of a method of forming a roll used for manufacturing the functional laminate, in a second configuration, roll-to-roll method.

[0809] It differs from the previous method in that the deposition of the so-called extracting composition is by ink jet 3012.

[0810] [Fig. 10] shows a schematic view of a method of forming the functional laminate roll in a second configuration, a roll-to-roll method.

[0811] The method for forming the functional laminate roll 1001' comprises:

[0812] - from the unwinding of a roll called the first interlayer unwinding roll 2002 comprising the first interlayer (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 print of the first interlayer (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,

[0813] - from the unwinding of a roll called insulating roll 2001', comprising the optical isolator layer 5, the first thermoplastic film 5' is here a carrier on the rear face (which will be oriented towards the face F2) of the optical isolator coating 5 and of the light extraction layer 6 coating with diffusing patterns) which is on the optical isolator coating (directly or via a protective layer (not shown), a second continuous drawing of the optical isolator layer with the light extraction layer, in strip, preferably with a guide roller 2011

[0814] - from the unwinding of a roll called the lower interlayer unwinding roll 2003 comprising the lower interlayer 32 preferably which is based on PVB (in sheet) plasticized with at least 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

[0815] - heating of the first interlayer 31 in strip form, by means of re IR 1111 resistors close to the band

[0816] - possibly heating of the lower interlayer 32 in strip form, medium IR 1112 resistors close to the band

[0817] - near the heaters, the formation of the laminated laminate by calendering in this order of the first heated interlayer 31, of the first film 5 (with coatings 5, 6), of the lower heated interlayer 32, with the diffusing patterns in contact with a calendering roller, in particular made of rubber

[0818] - after calendering, possibly one or more guide rollers 1000 and even cooling rollers dissement

[0819] - if necessary the insertion of a temporary protective polymer film 36 (anti adhesive) for example polyethylene, (PE)-, strip unwound 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.,

[0820] — winding the laminated laminate 215 onto the so-called winding roller 1001'.

[0821] A total cut along the edges of the strip laminate 215 and / or a cut lateral 190 can intervene.

[0822] The diffusing coating may be a hard coating with sufficient hardness (at least 1H) 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%.

[0823] [Fig. 11] shows a schematic view of a method of forming the functional laminate roll in a third configuration, a roll-to-roll method with in figures 10' and 10” laminate variants that can be obtained.

[0824] The method for forming the functional laminate roll 1001” comprises:

[0825] - from the unwinding of a roll called the first interlayer unwinding roll 2002 comprising the first interlayer (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 print of the first interlayer (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,

[0826] - from the unwinding of a roll called insulating roll 2001 '', comprising the optical isolator layer 5, the first thermoplastic film 5' is here a carrier on the rear face (which will be oriented towards the face F3) of the optical isolator coating 5 with a possible protective layer (not shown), a second continuous drawing of the optical isolator layer in strip form, preferably with a guide roller 2011

[0827] - from the unwinding of a roll called the lower interlayer unwinding roll 2003' comprising the lower interlayer 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 bonding with the first coated film 5,5' and a face opposite the bonding 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 bonding face), a third continuous printing separated from the first and second printings, printing preferably with guide rollers 2013, 2023, 2033

[0828] - heating of the first interlayer 31 in strip form, by means of re IR 1111 resistors close to the band

[0829] - heating of the lower interlayer 32 in strip form, by means of resistors IR 1111 near the band

[0830] - near the heaters, the formation of the laminated laminate by calendering in this order of the first heated interlayer 31, of the first film 5 (with coatings 5, 6), of the lower heated interlayer 32, with the diffusing patterns in contact with a calendering roller, in particular made of rubber

[0831] - possibly one or more guide rollers 1000 and even cooling rollers

[0832] - if necessary the insertion of a temporary protective polymer film 36 (anti adhesive) for example polyethylene, (PE)-, strip unwound 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.,

[0833] — the winding of the laminated laminate 216 onto the so-called winding roller 1001'.

[0834] A total cut along the edges of the strip lamination 215 and / or a cut lateral 190 can intervene.

[0835] The diffusing coating 6 may be a hard coating with sufficient hardness (at least 1H) 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%.

[0836] We can also do as a variant:

[0837] - a strip laminate 217 (see [Fig.l 1]') with the first film which is fluoropolymer 5” in particular corona treated (for example FEP in particular of 50pm) from the 2001” roll, 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,

[0838] -a strip laminate 218 (see [Fig. 11]”) with the diffusing coating 6 on the lower interlayer 32' (preferably diffusing coating by deposition by liquid for example here on the face opposite the bonding face), from roll 2003'.

Claims

1. Claims Method for manufacturing an illuminated laminated glass roof for a vehicle, particularly a road vehicle (100 to 710), comprising a transparent, curved laminated glazing unit comprising: - a first sheet (1), transparent, made of mineral glass, with a first main face Fl (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 neither in the visible - an optical isolator layer (5.5”), transparent, with a refractive index n2 in the visible such that n2 <nl, - 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 process 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 puff pastry 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 preferably of at least 0.3 mm - said optical isolator layer which comprises or is supported by a first transparent thermoplastic polymer film (5', 5”), of thickness Ep preferably at least 20pm and at most 200pm - the lower interlayer (32) of thickness Ei preferably at least 20pm.

2. Method for manufacturing an illuminable laminated glass roof for a vehicle according to the preceding claim, 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.

3. 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.

4. Method for manufacturing an illuminable 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), preferably a reflective prismatic film comprising a main face textured with reflective prisms (82, 83) and an opposite main face, called the smooth face, - another joining of said light redirection element, preferably of thickness Er<200pm, with the three-layer, another joining forming local bond(s) by local softening of the interlayer material of the three-layer, preferably by local heating, - and / or a pre-joining of said light redirection element, with a lamination interlayer frame, pre-joining forming local bond(s) by local softening of the interlayer frame of lamination, preferably by local heating and in that, preferably, the other joining and / or the pre-joining is before placement on the reference sheet, or even before placement on an additional functional element (9).

5. Method for manufacturing an illuminable laminated glass roof for a vehicle according to the preceding claim, characterized in that the light redirection element being 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 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, 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-bonding of the reflective prismatic film - with a main face of a lamination interlayer frame, - or within a lamination interlayer frame.,

6. Method for manufacturing an illuminable laminated glass roof for a vehicle according to claim 4, characterized in that 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, the reflective prismatic film preferably having a thickness Er<200 pm and even at least 70 pm, and it comprises the placement of the reflective prisms: - on a surface projecting from the three-layer, after partial cutting of the three-layer, - or on a main face of an intermediate lamination frame - or within an intermediate lamination frame, the thickness of the intermediate material receiving the reflective prisms preferably being at least 25 pm, the reflective prismatic film is preferably positioned to be placed next to or offset by at most 4 mm with the first film.

7. Method of manufacturing an illuminable laminated glass roof for a vehicle according to one of the preceding claims, characterized in that it

8. 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 the upper block, comprising an additional functional element (9) and a third thermoplastic interlayer of lamination (33), the additional functional element (9) which is a) an electroactive element, in particular based on liquid crystals, with another intercalary lamination frame (35) on the periphery of said electroactive element, in particular another intercalary lamination frame preferably in local adhesive contact with the third intercalary lamination layer (33), by local bonds, in particular local bonds by local softening of intercalary material, preferably by local heating (b) another functional polymer film bonded to 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. Method for manufacturing an illuminable laminated glass roof for a vehicle according to one of claims 1 to 6, 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 - the 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 placement so that the lamination interlayer frame is on the perimeter of both the functional additional 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.

9. Method for manufacturing an illuminable laminated glass roof for a vehicle (100 to 00) according to one of claims 1 to 6, characterized in that it comprises: on the reference sheet which is the second sheet (2), the placement of: - 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 on the third face, and an intermediate lamination frame (34) - preferably a joining of the intermediate frame (34) with the third face (13) by local bonds, in particular by local softening of the intermediate material,preferably by local heating - placing the functional laminate with the lower interlayer on the third face so that the interlayer frame is on the periphery of the laminate - preferably joining the functional laminate with the third face and even said interlayer frame by local bonds, in particular local bonds by local softening of the interlayer material, preferably by local heating - placing the first sheet (1) on the functional laminate and the interlayer frame.,

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

11. Functional laminate according to the preceding claim characterized in that the optical insulating layer comprises an optical insulating coating, in particular a matrix with porosities or hollow particles on a main face, preferably rear, 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.

12. Functional laminate according to claim 11 characterized in that it has a peel strength between the first film and the lower interlayer of at least 2N / mm.

13. Functional laminate according to claim 10 characterized in that the optical insulating layer is a fluoropolymer film, preferably corona treated, with a thickness Ep of at most 100 pm, preferably with a peel strength between the fluoropolymer film and the lower interlayer of at least 2 N / mm and even at least 3 N / m.

14. Functional laminate according to one of claims 10 to 13 characterized in that the lower interlayer is based on PVB with at most 15% plasticizers, with Ei of at most 50pm and carries the diffusing coating, on the main front face or main rear face.

15. Roll comprising the laminated functional laminate according to one of claims 10 to 14, in a wound strip, preferably with a width of at least 600 mm and / or a length of at most 300 mm and optionally comprising a temporary protective film.

16. A method of forming a roll of said laminate according to the preceding claim, which comprises: - a first continuous printing of the optical insulating layer in strip form with said first thermoplastic film, which is a first fluoropolymer film or a first thermoplastic film carrying an optical insulating coating, - a second continuous printing of the first interlayer in strip form, and in sheet form, having a smooth rear main face with a roughness defined by a parameter Rz of at most 50 pm, preferably a second printing separate from the first printing - a third continuous printing of the lower interlayer in strip form, the lower interlayer having a smooth front face with a roughness Rz defined by a parameter of at most 50 pm, in particular a third printing separate from or associated with the second printing, - 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 form 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.

17. Method for forming a roll of said laminate according to claim 16 characterized in that it comprises: - unwinding a roll called the first interlayer unwinding roll comprising the first interlayer layer (31) in strip form, preferably based on PVB - unwinding a roll called the insulating roll, comprising the optical insulating layer with said first thermoplastic film (5.5”, 5'), in strip form, the first thermoplastic film preferably carrying on the rear face the optical insulating coating and the light extraction layer which is on the optical insulating coating - unwinding a roll called the lower interlayer unwinding roll comprising the lower interlayer layer (32) preferably based on PVB with at least 20% plasticizer, with a thickness Ei of at least 0.3mm.

18. Method for manufacturing a functional laminate according to claim 16 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 with at least 20% plasticizer - the unwinding of a composite roll, comprising a laminated bilayer comprising the optical isolator layer with said first thermoplastic film and the lower interlayer which is based on PVB with at most 5% or 1% 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.

19. Method of forming a roll of said laminate according to one of claims 16 to 18, 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 - 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.

20. Method of forming a roll of said laminate according to one of claims 16 to 18, characterized in that it comprises: - the unwinding of a primary unwinding roll comprising said first thermoplastic film, in strip form, in particular 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 - liquid deposition on the optical insulating coating or on the lower interlayer (rear or front face) of a composition called an extracting composition comprising a matrix, in particular a crosslinkable one, and diffusing particles, layered in one or more patterns, to form the light extraction layer.

Images