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 ILLUMINABLE LAMINATED GLAZED ROOF FOR A VEHICLE WITH FUNCTIONAL LAMINATE, 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 LED lighting as described in document WO2010049638. The light emitted by the diodes is introduced edge-on into the inner 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 the outer glass, tinted and coated with a layer low refractive index

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

[0006] - a second interlayer laminate, based on polyvinyl butyral (PVB) without plasticizer, 30µm thick, which is functionalized by being coated with a light-extracting layer which is a printed ink containing 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 flexographic deposition of ink onto the second interlayer, which forms a temporary laminate with a 30µm temporary plastic film, for adhesion during printing, the layers being held together electrostatically. - the 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 top of the second interlayer.

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

[0010] To this end, the present invention first relates to a method for manufacturing a laminated (curved) glass roof for a vehicle, particularly a road vehicle (automobile: car, truck, public transport: bus, coach, etc.) or a railway vehicle (trains, metros, trams), comprising:

[0011] a curved laminated glass - transparent (at least in a clear (central) pane) - including:

[0012] - a first (convex), transparent, mineral glass sheet, possibly tinted, in particular gray or green, intended to form the outer glass, with a first layer and a first main face Fl (intended to be oriented towards the outside of the vehicle) and a second opposing main face F2, bare or coated with a transparent functional coating (in the clear part of the glass), the first layer in particular having a thickness of at most Ipm or 200nm, for a road vehicle and even a car, the first layer preferably having a thickness of at most 4mm, or even at most 2.5mm, or even at most 2.2mm - in particular 1.9mm, 1.8mm, 1.6mm and 1.4mm - and even a thickness of at least 0.7mm, for example with a refractive index nv of at least 1.5 in the visible spectrum

[0013] - a polymer laminate interlayer, transparent (at least in the light of central pane of glass - 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 the upper interlayer, i.e. in adhesive contact with the second face F2 or with a functional transparent coating (in particular of thickness of no more than Ipm or 200nm, in the clear pane) on the face F2, single or multilayer, in particular if acoustic PVB, or forming an intermediate interlayer, single or even multilayer), and a second interlayer called the lower interlayer (clear), thermoplastic (single or multilayer, in particular if acoustic PVB and the same coating)

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

[0015] - a second (convex) sheet, transparent (at least in the clear glass (central), made of mineral or polymer glass, preferably extra clear, with a refractive index of n / a in the visible, with (a second layer and) a third main face F3 and a fourth main face F4 opposite, preferably bare or coated with a functional (transparent) coating in the clear part of the glass, with a thickness of at most Ipm or 200nm, second sheet preferably made of mineral glass, third face F3 oriented towards 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 being preferably 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 face F3 preferably bare), and the light extraction layer being in contact with the lower interlayer and between the optical insulator layer and the face F3.

[0017] The laminated glass roof according to the invention further comprising, between face F2 and face F3, an optical insulating layer, with a refractive index n2 in the visible spectrum, 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 process comprises, in this order:

[0019] - an assembly step comprising:

[0020] - an arrangement on one of the first and second sheets, referred to as the sheet of reference of the first intercalated layer and the lower intercalated layer, (direct placement, in contact with the reference sheet or on one or more additional layers (electroactive or electro-optical element etc., as detailed later) especially 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, the lamination interlayer, the optical insulating layer, the light extraction layer, etc.).

[0023] According to the invention, the assembly comprises placing on the reference sheet a functional laminate comprising a laminated (pre-laminated) three-layer structure comprising, in this order:

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

[0025] - said optical insulating layer (recessed and encapsulated by the first layer interlayer and lower interlayer layer or with a free edge), said optical insulating layer comprising (even made of) or being supported by a first thermoplastic polymer film (non-adhesive, in particular polyester or polyolefin) of thickness Ep of at least 20µm, 30µm or 40µm and preferably of no more than 200µm, or better 125µm or even 100µm or 75µm (chosen according to its rigidity to facilitate the manufacture of the trilayer)

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

[0027] In addition, 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 visible area), with a refractive index n4 in the visible range, preferably n4 greater than or equal to ni or less than ni, with n4-nl of at most 0.1 or better yet of at most 0.05. Optionally, the roof has a blur 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] Firstly, the fact of carrying out the functional laminate upstream makes it possible to position only one element on the reference sheet rather than proceeding sheet by sheet.

[0030] Furthermore, unlike the prior art temporary laminate which requires the removal of the temporary film during placement, the functional laminate according to the invention may consist only of functional layers, without a sacrificial temporary layer. The functional laminate may be ready-to-use, available in rolls, and unrollable.

[0031] Furthermore, the three-layer construction incorporates the optical insulating layer, which allows, if necessary, the addition of a functional coating on the F2 face (solar control, etc.) and provides a more reliable optical insulating layer. In particular, controlling the thickness of the optical insulating film or the optical insulating layer coating on the first, flexible, flat film is easier than coating the first curved glass sheet.

[0032] For optimal integration, the three-layer also incorporates the light extraction layer, which can be located not only on the F3 face as in the prior art but also within the three-layer itself, in particular deposited on the first film (especially on an optical insulating coating). In particular, it may be desirable to avoid weakening the F3 face with a coating.

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

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

[0035] The first polymer film is chosen to be thin in particular to limit the local bulking effect. The first polymer film with an optical insulating coating or the optical insulator itself can be available in roll or sheet form.

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

[0037] - difficult to handle, with the risk of blowing 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 in case of cutting (when suctioning onto the cutting machine to the shape of the glazing etc).

[0040] Its destacking into sheets or its extraction from a roll would make it very electrostatic so that it attracts and catches dust, which requires working in a very clean environment or adding another electrostatic discharge step which makes it possible to cancel the electrostatic forces pinning the dust to the first film.

[0041] Conversely, since the first polymer film according to the invention is already protected by the interlayers of the laminated three-layer, the step of destacking or extracting a roll does not mechanically alter the first polymer film nor degrade the optical insulation function or the transparency.

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

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

[0044] Furthermore, all the layers of the three-layer laminate are positioned precisely 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 steps to the process.

[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 decreasing the probability of trapping dust or fibers and which would lead to the elimination of products for appearance defects, once the latter have reached complete transparency at the end of lamination (degassing, autoclave).

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

[0047] The proposed solution therefore consists of preparing the functional laminate with the laminated three-layer (and even laminate with one or more other laminated layers and / or bonded to another or other layers as described later) before placing it on the reference sheet in order to reduce the number of process steps, the time in particular in the cleanroom and to facilitate handling and quality control.

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

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

[0050] - or placed (preferably the first intercalated layer) on another layer (sheet etc.) in particular forming part of a stack (pre-assembled layers) or not), said upper block, in particular with one or more functional polymer films (thermoplastic, non-adhesive) and / or one or more electroactive elements (electrooptics); in particular based on liquid crystals, electrochromic, photovoltaic etc), and at least a third intercalated layer of lamination (intended to be placed on the first sheet of glass), the whole trilayer and upper block being able to be bonded (locally) before being placed on the reference sheet, preferably the second sheet of glass (face F3).

[0051] If necessary before placement on the reference sheet, preferably the second sheet of glass (face F3), the laminated triple layer is cut (partially or totally) and / or bonded with an interlayer frame at its periphery (from the 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 to maintain good adhesion after lamination.

[0053] The multilayer laminate can consist of the laminated trilayer or even include another or other layers attached to the laminated trilayer (in particular by local bonds, local heating of intercalated material etc) or even laminated layers (in adhesive contact with each other and) with the trilayer, the multilayer laminate is then a laminated multilayer of at least 4 or 5, 6 layers or even 7, 8 or 9 layers (in adhesive contact with each other).

[0054] Preferably, the multilayer laminate comprises at most 3, 2, or 1 additional interlayer laminates (in particular from additional interlayer sheets), at most two or one functional film (preferably transparent, polymeric), and / or an electroactive (or electrooptical) element, particularly one based on liquid crystals, electrochromic, or photovoltaic. In particular, the laminate comprises a laminated multilayer including: a third interlayer / functional film and / or an electroactive element (chosen to be laminateable) / three layers. In particular, the laminate comprises a third interlayer and an electroactive element (in contact with the first interlayer), the third interlayer being bonded to the first interlayer and / or to an interlayer frame around the perimeter 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 can be at most 8 mm or even at most 6 mm. The length L1 of the laminate can be at least 600 mm and preferably at most 2000 mm. The width W1 of the laminate can be at least 600 mm and preferably at most 1500 mm to be more manageable and compatible with roll-by-roll manufacturing. By For example, care is taken to ensure that a roller carrying the rolled laminate is not too heavy and / or long.

[0057] The overall shape of the laminate can be custom-made, in particular regular or irregular, and in particular homothetic to the shape of the glazing. For example, the laminate may be generally quadrilateral in shape, in particular rectangular, possibly with a rounded contour. The longitudinal edges of the laminate (and even of the first and second panes 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 whole, the adhesion between layers being achieved thanks to the intercalary adhesive material of lamination.

[0059] It is at least 0.3mm to facilitate the manufacture of the three-layer (given the flexibility of the interlayer material), to confer good cohesion properties of the glazed roof (and protection in case of breakage).

[0060] Of course, it is possible that in the laminated material, both before placement on the reference sheet and after the lamination of the glazing:

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

[0062] - the possible interface between an intercalated frame and the first intercalated layer or lower intermediate layer should be indistinguishable (especially if made of the same material and the same color)

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

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

[0065] The reference sheet is preferably the second (inner, convex) sheet, presented with its convex surface facing upwards, as this facilitates the positioning of the laminate. Positioning the initially flat laminate on a concave surface forces the laminate to curl, 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 is presented 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 bonded as already described to 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 PVB-based lamination interlayer (plasticized, unplasticized), by pressurizing preferably at least 5 bars and at most 14 bars and heating at least 100°C and at most 150°C, in particular by autoclaving.

[0069] The lamination process may include placing the glazed assembly under vacuum at room temperature in order to evacuate the air (degassing operation) between the two sheets of glass (between trilaminate or other sheet(s) etc.), then heating the glazed 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 airtight confinement of the entire periphery of the glazed assembly and suction in the confined peripheral volume.

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

[0073] For lamination, a sealed elastomer ring, equipped with an opening through which a vacuum is created by suction, is fitted, for example, around the entire peripheral area of ​​the glazed assembly. The sealed ring is often referred to by the English term "vacuum ring." The air present between the two cold glass sheets is then evacuated for a period of 15 to 45 minutes, followed by heating to a temperature of 80°C to 120°C for a period of 30 to 60 minutes.

[0074] An alternative to this last vacuum sealing step may consist of placing the glazed assembly in a vacuum chamber or vacuum bag, at least part of whose walls are 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] A peripheral element may be cited as an electrical connection element which is linked to an electroactive (electro-optical) element, in particular one based on liquid crystals, electrochromic, or photovoltaic, between the two glass panes. For example, such a connection element or other is located between the two panes and extends beyond the glass assembly (for example, along the edge of the glass 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 edge sealing problems, 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 sheets of glass, the main rear face means the face which is or is intended to be oriented towards the face F3, and the main front face means the face which is or is intended to be oriented towards the face F2.

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

[0079] -a bonding (which is preferably an adhesive contact)- preferably direct, without the addition of additional adhesive-, of an interlayer frame of thermoplastic lamination (material identical or chemically compatible with the material of the first interlayer and lower interlayer, frame of thickness Ec), with the three-layer, bonding preferably by local (point) bonds with an edge of the interlayer of at least one of the first interlayer and lower interlayer and possibly the free edge (of the first film),

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

[0081] The (local) softening is by application of a chemical solution such as alcohol or preferably by local heating (supply of heat giving cohesion throughout between frame / first film and between interlayer frame of lamination / interlayer layer).

[0082] Local connections, in particular spot welds, are made preferably following (or delayed) the contacting (or in close proximity to at most 5mm or 1mm if local heating) of the frame with the three-layer, possibly with a cut part of the three-layer (cut 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 trilayer (e.g., lateral and longitudinal),

[0085] - local connections preferably long, at least 1mm or 5mm and at most 30mm 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 interlayer frame for lamination is preferably, for handling purposes, monolithic (in one piece) or in several butted parts or even spaced at most 1mm apart, for example one or more parts (strips) carrying a light redirection element.

[0088] The interlayer frame for lamination can be at least 20 mm wide (for its integrity, handling and to ensure sealing) and preferably no more than 100 mm wide or 50mm, preferably with a thickness Ec of at least 0.3mm. It can be wide enough to secure a functional element such as a light redirection element described later.

[0089] Thus the bonding is preferably achieved by adhesive contact, not involving the addition of adhesive material, preferably by (local) softening of intercalary material which leads to adhesive contact between surfaces.

[0090] Advantageously, the bonding (the adhesive contact) is achieved by local heating and possibly also by pressure, in particular by 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 allowing heat to pass through, one or more heating fingers (made of non-stick material in particular silicone, polytetrafluoroethylene, elastomer etc), a hot air gun.

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

[0093] Typically with a soldering iron, the temperature is at least 200°C or 250°C and the soldering is fast and deep, without pressure necessary, with heated fingers the temperature is at least 100°C.

[0094] The contact areas for the local connections can be centered a few millimeters from the boundary (junction or gap of at most 1 mm), here between the frame and the trilayer, and on either side of the boundary. For example, a heating finger (10 mm) is centered alternately on the trilayer (5 mm from the boundary) and on the frame (5 mm from the boundary). To be more compatible with the speed of an industrial line, the various local connections, here between the frame and the trilayer (or any other connection with several local connections described later), can be made in a single operation.

[0095] Thus, the bonding (adhesive contact), here of the frame with the three-layer material, can be achieved in a single operation for all local bonds. A heating tool can be chosen that allows the various point adhesive bonds to be made in a single operation, for example, using heated fingers.

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

[0097] This method of joining is preferred to gluing by means of a bead of glue or double-sided adhesive, possibly a one-off connection.

[0098] Preferably all the interlayer material of the lamination is based on the same polymer, in particular based on PVB, preferably plasticized (conventionally) for the interlayer frame and the first interlayer layer.

[0099] The interleaving frame may be:

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

[0101] - multilayer (multi-layered) in particular with first and second colored layers distinct, notably the so-called upper layer (oriented towards face F2). opaque (for masking light etc).

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

[0103] The interlayer frame is not always necessary to protect the first film, particularly when in the three-layer Ep is at most 200pm and even at most 150pm or 100pm and the first polymer film is shorter (for example by at least 3mm, or 5 or 10mm and at most 30mm (possibly depending on the extent of the peripheral masking frame, defining the clear view) than the first interlayer and the lower interlayer layer, -therefore already encapsulated by these interlayer layers then in adhesive contact with each other-.. However, it is still possible to provide such a frame and the reinforcement 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 includes placing the trilayer on the reference sheet with said interlayer frame attached (linked by local bonds).

[0105] For example, the process includes: - Placement of the tri-layer (previously cut) inside the interlayer frame (previously cut from an interlayer) - on an editing table, preferably with the tri-layer inside the frame rather than placing the frame around the tri-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 intercalary frame on the reference sheet (with centering relative to it), - or placement of the laminate assembly linked to the intercalary frame on a layer, in particular of a stack of layers, bonding by local links, 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 is sufficiently and thinned to avoid breakage and bubbling. In particular, any functional element (first film, other polymer film) functional, electroactive element etc) of a thickness of at least 200pm intercalated between two intercalated layers and shorter is preferably surrounded by an intercalated frame between the two intercalated layers.

[0107] In particular, in the assembly process (with autoclaving), the interlayer material (PVB, etc.) has difficulty flowing over distances greater than a few millimeters. Any localized excess thickness of the glazing (due to an element) would cause deformation of the first and second glass panes. Consequently, various undesirable phenomena may occur: - the breakage of one of the two lenses, due to excessive deformation of the latter, inducing excessive local extensional stresses; - bubbles introduced into the glazing, due to imperfect lamination 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 small molecules present in the PVB etc).

[0108] If necessary, the process may include a partial peripheral (circumferential) cut of the trilayer (of the laminate), which is a total cut 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 protruding preferably of width W1 of at least 20mm (and preferably of at most 200mm) from the other of the first interlayer and lower interlayer, called the full layer.

[0109] To limit the risk of breakage or bubbling, the process further includes, when E' > 200 µm and even E' > 150 µm or E' > 100 µm, the placement of an interlayer frame (for easier handling without creases, etc., preferably with a width Wc of at least 20 mm, in particular Wc less than or equal to the width Wl, and / or a thickness Ec of at least 0.3 mm) on the protruding frame surface. In particular, during lamination, the first film is encapsulated by the 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 by at most 5mm or 1mm).

[0111] This divider frame can be used for:

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

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

[0114] - and / or by 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, known as the back face, of the lower interlayer (oriented towards face F3 after placement on the reference sheet), or offset by at most 100pm (under-flush or over-flush).

[0116] During lamination the first film is encapsulated (coated) by interlayer material (by thinning the interlayer frame and / or the entire layer).

[0117] In particular, when the back (free) face of the lower interlayer does not carry the light extraction layer, and the lower interlayer is specifically PVB-based with at least 20% plasticizers, it may be desirable for the back (free) face of the lower interlayer to have minimal roughness, promoting outgassing and satisfactory lamination. In particular, the roughness parameter Rz is at least 1 Opm or even 50 µm.

[0118] In particular, for PVB-based materials with at least 20% plasticizers, it may also be desirable for the front (free) face of the first interlayer (oriented towards face F2 after placement on the reference sheet) to have minimal roughness, promoting outgassing and satisfactory lamination. In particular, the roughness parameter Rz is at least 1 Opm or even 50 µm.

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

[0120] It is also possible to perform a complete cutting of the laminate (of the entire laminated portion of the three-layer or more laminate) (preferably before any local bonding) to a predetermined shape. In particular, it is possible to perform a complete cutting of the three-layer (preferably before any local bonding of the three-layer with another element such as the interlayer frame, etc.) to a predetermined shape.

[0121] Preferably, an automatic cutting system is implemented, itself composed of a table, possibly a conveyor belt, a blade supported in a swiveling tool which is itself attached to a horizontal (XY) carriage-type movement system mounted on a bridge and enabling cutting:

[0122] -an interlayer of laminated material to form the interlayer frame

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

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

[0125] Preferably, to hold the element to be cut, suction is applied by means of holes in the carpet.

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

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

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

[0129] The second configuration is preferred because:

[0130] - have the edge of the interlayer slightly recessed relative to the edge of the limiting glass light leaks through the edge of the glass,

[0131] - the first and second slices (of the glass sheets) are preferably 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 deburr or brush avoids operations and therefore yield losses,

[0133] - deburring and brushing a thick multilayer interlayer is more complex.

[0134] The method may further include:

[0135] — the provision of at least one light redirection element, in particular in periphery of the clear glass, in particular two light redirection elements (especially at the periphery of the clear glass on two opposite edges), preferably a (prismatic) light redirection element which is a reflective prismatic film having a textured main face with reflective prisms and an opposite main face, called the smooth (non-textured) face,

[0136] - another method of joining (which is preferably an adhesive contact) of direct bonding, without additional adhesive, of said light redirection element (light redirected towards face F3) with an interlayer material of the trilayer (first and / or lower interlayer), in particular by local bonding(s), other bonding forming local bonding(s) by local softening of the interlayer material of the trilayer, preferably by local heating,

[0137] - and / or a pre-bonding (which is preferably an adhesive contact) said light redirection element (light redirected towards face F3) with a Interlayer material of a laminated interlayer frame (frame already bonded to the trilayer or subsequently bonded to the trilayer, in particular the bonding already described), in particular pre-bonding forming local bond(s) by local softening of the laminated interlayer frame, preferably by local heating

[0138] In particular (as for the frame / three-layer bonding already described), the local bond(s) are at least 1mm or 5mm long and at most 10mm long and spaced at least 10, 15cm and at most 80, 50cm apart.

[0139] It may be desirable to limit the number of local bonds so as not to alter the optical function of this light redirection element (transparency, etc.). For example, a maximum of 1, 2, or 3 local bonds are used.

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

[0141] Softening (locally) can be achieved by applying a chemical solution such as alcohol or, preferably, by local heating (generating adhesion, adhesive contact between the light redirecting element and the interlayer material). Local bonds, particularly spot welds, are preferably made following (or after) the contact (or within a maximum of 5 mm or 1 mm if local heating) of the light redirecting element with the interlayer material.

[0142] Preferably the other bonding and / or pre-bonding is before placement on the reference sheet or even before placement 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 intercalated material.

[0144] The light redirection element is adapted to receive light (from a row of diodes, etc., at the normal angle to the glazing or at an angle) on the F4 face, passing through the second sheet, and reflecting it back towards the second sheet by total internal reflection. The light redirection element is elongated to receive light, for example, from a row of diodes (preferably a straight strip at least 5 cm long, in one or more sections, connected or not).

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

[0146] In order to avoid creases, 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 1.5m.

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

[0148] The substrate film or base of the (micro)prisms can be less than 200 µm, 100 µm, 80 µm or 50 µm thick, and even at least 30 µm thick. 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 be of a height of at least Ipm and preferably of at most 100 or 50pm or 30pm.

[0150] Preferably, the prismatic (reflective) part of the reflective prismatic film is on, or even in contact with, the interlayer material (of the first interlayer, the lower interlayer, the frame) to protect the vertices, and even sinks into the interlayer material during lamination (in the case of a slight overthickness). A thickness of this interlayer material of at least 25 µm is preferred, and better still 50 µm or 100 µm.

[0151] The light redirection element, in particular the (first) prismatic reflector film, may be below the first film or adjacent to the first film possibly slightly offset in height from the first film.

[0152] The (first) prismatic reflective film may extend along the first longitudinal edge, preferably at a constant distance from the clear glass (inner edge of the peripheral masking frame) or from a first lateral edge (at the front or rear of the roof). Several prismatic reflective films may be joined or separated along a first edge.

[0153] One can add (at least) another (second) prismatic reflector film on a second edge in particular edge opposite to the first edge, in particular film similar or identical to the first prismatic reflector film, opposite the first prismatic reflector film.

[0154] In a first configuration, the light redirection element is a reflective prismatic film, having a textured main face with reflective prisms and an opposite main face, called the smooth face, preferably of thickness Er <200 µm or at most 150 µm and better still at least 70 µm, with the textured face oriented towards the first interlayer (smooth face oriented towards the lower interlayer, towards face F3). The reflective prismatic film is positioned to be opposite, adjacent to, or offset (distant) by at most 4 mm or 1 mm from the first film. (with its outer edge), and the optional optical insulating coating is preferably up to the edge of the first film or set back by no more than 1 mm from the edge of the first film

[0155] a) before the other bonding with the trilayer, a contacting (a laying) of said reflective prismatic film (of the smooth face, here rear face) on a principal rear face of the lower interlayer, intended to be oriented towards the F3 face, the reflective prismatic film is preferably positioned to be at least partially 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 F3 face (preferably in contact with)

[0157] b) or, before or simultaneously with the bonding to the trilayer, the pre-bonding of the reflective prismatic film (of the smooth face, here rear face):

[0158] - with a main face (front or back) of an interlayer laminated frame

[0159] - or within an interlayered laminated frame, in particular multilayer (multi-layered), preferably based on plasticized PVB (with at least 20% plasticizer).

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

[0161] When the prismatic reflector film is positioned to be adjacent to the first film, attached or at most 4mm or 1mm away, preferably, the base or the top of the reflector prisms (oriented towards the first interlayer) of the prismatic reflector film is preferably above at most 30pm (from the front face of) the optical insulating layer, in particular (from the front face of the first film).

[0162] In one configuration, the prismatic reflector film can be positioned straddling the rear free face of the trilayer and the rear face of the interlayer frame (in particular already attached to the trilayer).

[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 can be on the front face of the frame and, preferably, the textured face (the reflecting prisms) is 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 having a textured main face with reflective prisms and an opposite main face called the smooth face, preferably having a thickness Er of less than 200 µm or at most 150 µm and even at least 70 µm, and the method includes the placement of the reflective prisms:

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

[0167] - on the main face of an interlayer frame (attached to the trilayer or bonded then as already explained), in particular the main front face intended to be oriented towards face F2

[0168] - or within an intercalated frame, in particular multilayer (multi-layered), of Preference for a plasticized PVB base (with at least 20% plasticizer) - (bonded, integral to the trilayer or bonded, integralized subsequently)

[0169] The thickness of the interlayer material receiving the reflecting prisms is preferably at least 25pm and better at least 30pm, 50pm or 80pm (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 interlayer frame of lamination or of a third interlayer layer of lamination (of said interlayer of lamination).

[0171] The prismatic reflector 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 prismatic reflector film is positioned to be adjacent to the first film, attached to or at most 4mm or 1mm away from the first film, then preferably the bases or the apexes of the reflector prisms (oriented towards the lower interlayer, towards face F3) are preferably above at most 30pm (from the front face) of the first film or even of the optical insulating coating (redirecting 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 transmission redirection element on the F4 side (prism, prismatic film etc).

[0175] The prismatic film (reflector side F3, or in transmission and side F4) 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, especially one based on liquid crystals or electrochromic or even photovoltaic (solar cells) surmounted of a third interlayer of the lamination interlayer, coming into contact with the bare F2 face or with a transparent electroconductive functional coating on the F2 face.

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

[0179] A lower block may include the laminate and optionally an interlayer frame bonded to the trilayer, in contact or better bonded (locally) to the upper block (by softening of interlayer material, for example interlayer frame and / or other interlayer frame).

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

[0181] -the supply of an additional stack, referred to as the top block, comprising an additional functional element and a third interlayer of thermoplastic lamination (of said interlayer of lamination), preferably plasticized PVB (at least 20% plasticizer)

[0182] the additional functional element which is:

[0183] a) an electroactive (electro-optical) element, in particular liquid crystal-based or electrochromic or photovoltaic (solar cell-based), with another interlayer laminated frame around the periphery of said electroactive element, in particular another interlayer laminated frame preferably in local adhesive contact with the third interlayer laminate, by local bonding, in particular local bonding by local softening of the interlayer material, preferably by local heating

[0184] b) another functional polymer film bonded (laminated) or in contact with the third interlayer laminate, (mono or multi-film, in particular solar control, in particular with a polymer film with a 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 veneer with an interlayer frame integral with the trilayer and / or light redirection element(s) integral with the trilayer, thus forming the lower block

[0186] - an additional securing of the lower block with the upper block of preference additional bonding forming local bonds by local softening of intercalated material, preferably by local heating.

[0187] In an embodiment, the process may include:

[0188] -the supply of a third thermoplastic interlayer (of said lamination interlayer), preferably in sheet form and even of a thickness of at least 0.3mm

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

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

[0191] - of an additional functional element, which is an electroactive element, in particular based on liquid crystals, electrochromic or photovoltaic, or another functional polymer film,

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

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

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

[0195] In an embodiment, the process may include:

[0196] on the reference sheet, which is the second sheet, the placement: - at least one light redirection element, in particular a prismatic reflector film with a textured main face and an opposite main face described as smooth on the third face, and an interlayer laminated frame - preferably, a bonding (preferably by adhesive contact) of the interlayer frame to the third face by local bonds, in particular local bonds by local softening of the interlayer material, preferably by local heating - the placement of the trilayer (of the functional laminate) with the lower interlayer on the third face so that the interlayer frame is on the periphery of the trilayer (of the functional laminate) - preferably, a bonding (adhesive contact) of the trilayer (of the functional laminate - in particular the lower interlayer) with the third face and even the interlayer frame itself, by local bonding, in particular by local softening of the interlayer material, preferably by local heating - the placement of the first sheet on the functional laminate and the interleaving frame.

[0197] It is thus possible to prepare in parallel (or one after the other on the same assembly table)

[0198] - the additional stacking, the top block (cutting, local links with other interleaving frame for lamination etc.)

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

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

[0201] In particular, it is preferred to place the laminate (lower block) on the additional stack (upper block), to join them (locally), to turn the whole thing over -manually or by robot(s)- and to place it on the second sheet (face F3) which is the reference sheet.

[0202] Indeed, in the case of an additional stack which includes an electroactive element with an interlayer frame attached by local bonds to the third interlayer layer, it is preferable to place the laminate on the additional stack rather than the other way around when the electroactive element is not (always) attached to the third sheet (in its central part) it cannot be easily turned back towards the assembly table.

[0203] The cutting (of the frame and the trilaminate) is preferably carried out off the laminate lamination line (by roll process, roll to roll preferably), in a clean atmosphere as are the local bondings.

[0204] In order to ensure that the various elements remain securely joined and positioned relative to each other during the rest of the process, one can also provide for joining by local bonding, (local) softening of intercalated material: - after placement on the reference sheet (especially if the second sheet) bonding with the reference sheet of the laminate alone or of a complete block (including the upper block and the lower block) - and / or after placement of the other sheet of glass, (possible) bonding with the other sheet of the laminate alone or of the complete block (comprising the upper block and the lower block).

[0205] When the reference sheet is the second sheet, the lower interlayer comes into contact with the bare face F3 preferably 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 intercalated layer.

[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 intercalated layer.

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

[0209] -between the optical insulating layer and the lower interlayer with a coverage rate preferably of no more than 30% (for cohesion).

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

[0211] Each interlayer of thermoplastic polymer laminate can be selected from polyvinyl butyral (PVB), or even polyvinyl acetate (PVA), ethylene-vinyl acetate (EVA), polyurethane (TPU) alone or in mixtures of several varieties of one or more of them; the term "varieties" here refers to variations in plasticizer content, branching / linearity, average molecular weight of molecules...

[0212] Of course, it may be 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 laminates may be an acoustic PVB, in particular

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

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

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

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

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

[0219] The interleaving 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 trilayer (it may be longer or shorter along all or part of its edge). In any case, it is preferable that the edges of the trilayer and the electroactive element, the third interlayer sheet (and even the interlayer frame(s) and any light redirection element, in particular a prismatic reflective film) be 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 as EP0876608B1 and WO2011033313A1, and PDLC elements (PDLC = Polymer Dispersed Liquid Crystal), known for example as DE102008026339A1. There are also electrochromic elements, known, for example, as 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 of polypropylene or polyethylene, which serves to protect the carrier films from dirt or scratches.

[0223] In a particularly preferred embodiment, the liquid crystal-based element is a PDLC (polymer dispersed liquid crystal) element. The PDLC element contains liquid crystals that are incorporated into a polymer matrix. If no voltage is applied to the PDLC element, the liquid crystals are randomly aligned, leading to strong light scattering through the active layer (translucency). If a voltage is applied to the PDLC element, the liquid crystals align in a common direction, and light transmission through the functional element is increased (transparency). However, it is also possible for the liquid crystals to be ordered in an unconstrained state and to become disordered accordingly when a voltage is applied. Other functional elements can also be used whose optical properties are based on liquid crystals, such as PNLC (polymer networked liquid crystal) elements.If, in relation to the PDLC element, we are talking about the application of a voltage, then an alternating voltage (the RMS 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 a suspended particle device (SPD). The SPD contains suspended particles. The suspended particles change the optical state of the functional element by absorbing light when a voltage is applied. SPD functional elements therefore have switching states with transparent and opaque optical properties, as well as intermediate stages between transparency and opacity. If, in relation to the functional element as an SPD, the application of a voltage is mentioned, then an alternating voltage (the RMS 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 ion placement. The ions are released, for example, from 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 ion migration. 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 DC voltage is applied to the functional element. A DC / DC converter is used to achieve voltages from 1 V to 50 V, and preferably from 10 V to 42 V, but it can be part of the control unit as required.

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

[0228] The slice of the functional element and that of the coated substrate may be aligned or separated by a maximum of 10cm or 5cm or 1cm.

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

[0230] The internal masking layer can be 2 mm or 3 mm (less than 5 mm) from the edge of the glazing or even right up to the edge. The masking layer can be a band framing the glazing (windshield, roof, etc.), particularly in black. Opaque coating is applied around the entire perimeter to conceal bodywork elements or seals, or to protect an adhesive for mounting on the vehicle. This internal masking layer is in contact with the second main surface. This internal masking layer defines the clear area of ​​the glazing. It can be advantageous for the outer edge of the optical insulating coating, or more broadly any adhesive layer of the laminate interlayer, to be masked by the internal masking layer and not be within the clear area of ​​the glazing.It can be advantageous for the external and even internal edges of the frame layer to be masked by the internal masking layer, so that they are not in the clear view of the glass, and 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, referred to as the inner layer, may be on the fourth face, referred to as F4, on the passenger compartment side, facing the inner masking layer (and may even be of the same nature, for example, a black enamel on a second sheet of mineral glass). It may be adjacent to a possible transparent functional coating, particularly athermal, at least in the clear part of the glass.

[0233] In particular for a motor vehicle roof (first sheet is the outer glazing):

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

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

[0236] Preferably, with regard to the light extraction layer, the diffusing particles (dielectric, organic or mineral, for example metal oxides) have a particle size defined by D90 less than 2 pm, preferably of at least 100nm and even at most 700 nm, in particular 400 nm ±100nm.

[0237] Preferably, the scattering particles are chosen from non-luminescent TiO2, SiO2, CaCO3, ZnO, Al2O3, and ZrO2 particles. Preferably, the particles have a (high) refractive index, greater than or equal to 1.8 or even 2 (greater than n5, in particular, by at most 1.8 or 1.7).

[0238] The invention also relates to a functional laminated laminate (usable in the process described above) with a thickness of at most 8 mm or even at most 6 mm, comprising a multilayer assembly which, according to the invention, includes a laminated three-layer component comprising, in this order:

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

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

[0241] - a second interlayer of laminated material, referred to as the lower interlayer, thermoplastic, with an Ei thickness of at least 20 µm (mono- or multi-layered, particularly laminated if acoustic PVB) and preferably no more than 1.2 mm

[0242] the laminate being equipped with a light extraction layer which includes and even in the form of a diffusing coating (on lower interlayer, on front face (optical insulating layer side) or opposite rear face).

[0243] In a first configuration, the optical insulating layer comprises an optical insulating coating, preferably on a principal, preferably rear, face of the first film. The first film is a polyester film, in particular PET, or a polyolefin film (including polycarbonate) of 50µm to 100µm.

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

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

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

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

[0248] The optical insulating coating can be an organic matrix (crosslinked material etc.) or mineral (silica etc.) with porosities or hollow nanoparticles (silica etc.) or (sufficiently) low index by its matrix itself.

[0249] Preferably the optical insulating coating is:

[0250] -a hard coat, thanks to its matrix,- in particular which is not susceptible to being damaged by the lamination process of the laminate,

[0251] Thus the optical insulating 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 insulating coating, preferably with a thickness of at least Ipm.

[0253] Advantageously, to further increase luminance:

[0254] -the difference in refractive indices nl-n2 is at least 0.08 in the visible and preferably 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 insulating 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 products (less easy at very low index), it may be desirable 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 insulating coating may comprise at least 99% by weight of crosslinked polymer, optional photoinitiators, rheological agents.

[0258] The optical insulating coating is preferably deposited by liquid means.

[0259] The surface of the optical insulating coating (before assembly) is non-sticky and involving the use of a lamination interlayer. The surface is then, in particular, non-sticky to the touch when placed on glass.

[0260] The optical insulating coating is, in particular, a varnish which can be obtained from a photocurable resin and with photoinitiators if necessary, or from a thermocurable resin, a two-component mixture, etc. A layer of crosscurable resin is deposited on the first polymer film. Once the material is crosscured, the free surface is not sticky.

[0261] In particular, the optical insulating coating comprises (is made of) a crosslinked polymer matrix with said index n2 preferably of at most 1.42 (or 1.4 or 1.35), matrix preferably among polyacrylate-based polymers (for example to have a refractive index of at most 1.42 or 1.4) with optional fluorinated function (to have the lowest possible refractive index), in particular urethane acrylate or fluorourethane acrylate or fluorosilicone 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, of volatile silicone component (source of surface pollution).

[0264] The crosslinked polymer material (of the optical insulating coating) may preferably be based on (or essentially composed of) a polymer combined with one or more other functional groups, such as the acrylate group for photo-crosslinking (crosslinked polymer material based on urethane acrylate or silicone acrylate) and / or the fluorine group to lower the refractive index (crosslinked polymer material based on fluorourethane acrylate or fluorosilicone acrylate). Thus, the crosslinked polymer material of the optical insulating coating is preferably a polymer based on acrylate, urethane acrylate, or even silicone or silicone acrylate, the polymer also having a fluorine group.

[0265] The optical insulating coating according to the invention may, in particular, be a liquid-based coating obtained from a formulation preferably photocurable by ultraviolet (UV, in particular UVA) or a two-component coating cured by chemical reaction. UV(A) curing is preferred because it is faster and the equipment is less expensive / more compact than that used by chemical reaction.

[0266] In a first example of an optical insulating coating, a UV curable acrylate-based resin is deposited on the first polymer film.

[0267] In a second example of optical insulating coating, a one-component UV curable resin based on acrylates (urethane acrylate) is deposited on the first polymer film.

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

[0269] The optical insulating coating (clear or tinted) may comprise, or even is composed of, a matrix with a refractive index n2m greater than n2 and less than n1 or n'1, and preferably with n2m of at most 1.48 and n2 preferably of at most 1.42, and comprising (nano)porosity and / or low-index (nano)particles, in particular hollow ones with an external diameter of at most 300 nm or even at most 100 nm, for example, hollow silica nanoparticles. Preferably, the optical insulating coating is free of free silicone and volatile silicone components (a source of surface pollution).

[0270] The matrix may be organic, in particular crosslinked polymer or thermoplastic, in particular selected from polymer based on polyacrylate, polyepoxides, polyvinyl acetate, polyester, polyurethane, PVB or the matrix may be mineral in particular silica.

[0271] We can cite the already described low index polymers if we want to lower n2 further.

[0272] The optical insulating coating comprises in particular at most 60% by volume fraction of (nano)poroses 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 insulating coating is a polymer and the matrix of the diffusing coating (in contact with or even deposited on the optical insulating coating) is a chemically compatible polymer (identical or similar polymer).

[0274] For example, the matrix of the optical insulating coating is a polyacrylate polymer and the matrix of the diffusing coating (in contact with or even deposited on the optical insulating coating) is a polyacrylate polymer.

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

[0276] For example, a protective coating (in contact with or even deposited on the optical insulating coating) is a polymer (polyacrylate etc.) and the matrix of the diffusing coating (in contact with 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 insulating layer is a fluoropolymer film with an Ep preferably of at most 100 µm, preferably corona-treated, preferably the interlayer material of the trilayer (of the lower interlayer, the first interlayer, and even of an interlayer frame), is PVB-based, 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 of at least 3 N / m

[0278] The fluoropolymer film may be based on or even made of one of the following materials: perfluoroalkoxy PFA, in particular with an index of about 1.3, poly(vinylidene fluoride) PVDF, in particular with an index of about 1.4, ethylene chlorotrifluoroethylene ECTFE, ethylene tetrafluoroethylene ETFE, more precisely poly(ethylene-co-tetrafluoroethylene, in particular with an index of about 1.4, perfluorinated ethylene propylene copolymer FEP or (Fluorinated Ethylene Propylene in English) in particular with an index of about 1.3 or polytetrafluoroethylene PTFE in particular with an index of about 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 insulator with a possible protective overlayer (dense) of the optical insulating coating (porous etc).

[0281] Preferably the diffusing coating is:

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

[0283] - is not susceptible to sticking (to the calender, to the roller of a roller 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 PVB-based with 0% to 15% or 10% or 5% plasticizers, with Ei of no more than 50pm and carries the diffusing coating on the main front or rear face.

[0286] The laminate may comprise the three-layer laminate or even comprise a multi-layer laminate 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 functional transparent film (electroconductive, passive, sandwiched between two interlayers) or at most 2 functional transparent films (electroconductive, passive, sandwiched between two interlayers) and / or an electroactive element (in particular based on all-solid electrochrome).

[0287] In particular, the laminated multilayer comprises:

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

[0289] -a functional polymer film, for example 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 bearing electroconductive layers forming electrodes, for example polymer film with electrode)

[0290] - a third intercalary layer of lamination.

[0291] Any electroactive element suitable for undergoing lamination by calendering (rather an electroactive element in sheet form upstream of the calender or resulting from the unwinding of a roll) can be included in the laminated material. In particular the electroactive element comprising a first thermoplastic film (or even thin glass called "UTG" in English, with a thickness of at most 0.3mm), in particular polyester (in particular PET, preferably of at most 0.3 or 0.2mm etc), with a first electroconductive layer (transparent) for example transparent layer of oxide(s) (TCO) such as indium tin oxide (ITO), or silver stacking 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 0.3mm), in particular polyester (PET, of at most 0.3 or 0.2mm etc), with a second electroconductive layer (TCO such as TITO, silver stacking etc).

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

[0293] In particular, the multilayer comprises

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

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

[0296] - a third intercalated layer (upper intercalated layer), attached to the three-layer.

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

[0298] The functional laminate may include an interlayer lamination frame around the perimeter of the trilayer (of the multilayer) and locally in adhesive contact with the trilayer.

[0299] The functional laminate may include at least one light redirection element (as already described), in particular of thickness Er < 200pm and even of at most 150pm and better of at least 70pm and in particular of the interlayer material (of the trilayer and / or of an interlayer frame bonded to 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 an overhanging frame surface filled by an interlayer frame of variable shade possibly opaque over all or part of its thickness.

[0301] The laminate can also include a masking layer, for example an ink (printed) which is opposite the light redirection element to prevent the exit of stray light opposite Fl, passing through the (imperfect) reflective film.

[0302] The interlayer frame carrying the light redirection element may include an opaque area (in bulk, 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 include an opaque area (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 cutting), thus including at least the laminated three-layer, laminate of width of at least 600mm, and / or of length of at most 300 or 500mm and possibly comprising a temporary protective film.

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

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

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

[0308] -an extrusion of the lower interlayer layer (in sheet form, for example plasticized PVB, usual) self-supporting or on a possible carrier substrate (temporary etc.), or a liquid deposition of the lower interlayer layer (for example PVB with little or no plasticization) on a carrier substrate (temporary etc.),

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

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

[0311] The formation of a roll of said laminate may involve:

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

[0313] - a roll process resulting from several roll-to-roll processes in succession and / or of rolling 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 functional laminate roll, in particular a roll-to-roll process, comprising:

[0316] - a first continuous drawing of the optical insulating layer in strip, with said first thermoplastic film having a main rear face with a roughness Rz of no more than 50pm (and a front face for example with a roughness Rz of 50pm or more), which is a first fluoropolymer film or a first thermoplastic film, in particular polyester (preferably PET), bearing an optical insulating coating (for example a hard layer or "hard coat" in English or even with a hard, transparent protective coating, compatible with the lower interlayer),

[0317] - a second continuous printing of the first interlayer layer in strip, and in sheet, having a smooth rear face with a roughness of Rz of no more than 50pm (and a front face with a roughness of Rz, for example, of 50pm or more), preferably a second printing separate from the first printing (first interlayer and optical insulator 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 strip) having a smooth front face of roughness Rz of no more than 50pm (and a back face of roughness Rz for example of 50pm or more), in particular third printing separate from the second printing (two independent strips) or associated with the second printing (lower interlayer on first film, forming composite strip, bilayer)

[0319] - heating the first interlayer (with a temperature adjusted in (depending on the intercalated material),

[0320] - heating of the lower interlayer (independent strip or strip composite), (with a 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 insulator layer in the form of a diffusing coating (in particular an 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 material 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] - the rolling of the laminated material onto a roller called a rolling roller.

[0324] We prefer to produce the laminated puff pastry by a rolling process rather than a sheet-by-sheet assembly followed by autoclave lamination to improve the handling of thin films in the roof manufacturing stages, limit the risks of pollution on the thin films, limit creases, for less waste.

[0325] We also prefer to use one or more rolls rather than pre-cut sheets conveyed before calendering.

[0326] The process for forming a roll may further include insertion into the calender (to form the laminate):

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

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

[0329] - or even a functional laminated 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 heated interlayer, the first film, the lower interlayer (optionally heated, independent sheet)

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

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

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

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

[0337] Calendering, preferably at room temperature, is fastest 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, for example by passing over cooled roller(s).

[0339] The roll formation process may include the insertion of a temporary protective polymer film (anti-stick) for example polyethylene (PE)-, unwound strip 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 ensure reliable unwinding of the strips, inflatable 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 can be a hard coat with sufficient hardness (of 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 intercalated layer (only possibly single-layer or multi-layer (e.g., acoustic PVB), the tension (in N / m) of the first film, or even the tension (in N / m) of the lower interlayer, controlled to unwind correctly, maintaining sufficient tension in order to to ensure that the band is held securely across its entire width, while avoiding material stretching.

[0347] - and / or the tension (in N / m) of a first film / intermediate layer bilayer lower (or first film / first interlayer) driven so as to unwind the bilayer correctly, maintaining tension to ensure that the tape is held firmly across the entire width, while avoiding material stretching.

[0348] - the (linear) pressure applied by the calender, preferably of no more than 3500 N / Mr.

[0349] Feedback control of the voltages, heating element(s), and pressure can be provided.

[0350] Several rollers can be used before and after the calender, in particular:

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

[0352] Heating can be done by:

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

[0354] - hot air

[0355] - microwave

[0356] - passage between heated rollers.

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

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

[0359] In an alternative configuration, the lower interlayer or the first interlayer is already laminated with the optical insulator layer (thus there are only two distinct prints among the three aforementioned prints before calendering for the trilayer).

[0360] In a first embodiment, the roll formation process (is roll-to-roll) and comprises, for the (three) castings:

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

[0362] - (for the second drawing separate from the first drawing) the unwinding of a so-called roll insulating roll comprising the optical insulating layer (low index) with said first thermoplastic film in strip form, the first thermoplastic film is preferably carrier on the back face of the optical insulating coating and of 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 the lower interlayer roll comprising the lower interlayer layer in strip form preferably which is PVB-based with at least 20% plasticizer, of thickness Ei of at least 0.3mm

[0364] Alternatively, the unwinding of a roll referred to as a lower interlayer roll comprising the lower interlayer layer in a strip, the lower interlayer layer being PVB-based with a maximum of 10%, 5%, or 1% plasticizer, having a principal bonding face with the first film and a face opposite the bonding face. The principal bonding face is provided with the light-extracting layer (diffusing coating), or the opposite face is provided with the light-extracting layer, preferably a 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 extraction face is intended to be the rear face, extraction face possibly in contact with the calender.

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

[0367] In particular if Ei is less than 50pm, 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 extraction face, the sacrificial polymer sheet being bonded by electrostatics (low adhesion) and removed before calendering.

[0368] It all depends on the winding on the lower interleaf unwinding roller, the light extraction layer can be in contact with the calender or optical insulating layer side.

[0369] In a second embodiment, the roll formation process (is roll-to-roll) and comprises (for castings):

[0370] - (for the first printing) the unwinding of a roll called the first unwinding roll of interleaving comprising the first interleaving layer (31) in strip form, preferably which is PVB-based 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 insulator roll, comprising a laminated bilayer including the optical insulator layer with said first thermoplastic film, in strip form, and the lower interlayer layer (sheet or coating) which is PVB-based with at most 5% or 1% plasticizer, of thickness Ei of at most 80 µm, having a principal face for bonding with the first film and a face opposite to 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 of the first interlayer.

[0373] The process for forming a roll of the laminate may include (upstream of the second drawing, the formation of the insulating roll):

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

[0375] - the liquid deposition of a composition called an insulating composition to form the optical insulating coating, preferably during said initial printing, 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 nano) hollow particles

[0377] - liquid deposition on the optical insulating coating (directly or on the overlayer) of a composition called the extracting composition comprising a matrix, particularly an organic one, that is crosslinkable (photo or thermocrosslinkable) and diffusing particles, forming one or more patterns, to form the light extraction layer (after hardening, crosslinking) particularly during the initial print or as a rework during a subsequent print

[0378] - a possible winding of the first film with the optical insulating coating and the light extraction layer in a winding roller, a roll that can be unwound for the second printing. 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 extraction composition takes place (at room temperature) - before the heating and calendering process.

[0379] The main known techniques for deposition of 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 by inkjet.

[0385] In particular, one can make a deposition by spinning (spin coating), or with a film puller, by curtain or via a flat die (slot die in English) which has a nozzle with an exit slot (straight etc), with a Meyer bar or by photogravure.

[0386] In one embodiment, the deposition is achieved 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, 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-to-roll process, the insulating composition is preferably deposited by a flat die, by a gravure roll, or with a Meyer bar.

[0388] The process for forming a roll of the laminate may include:

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

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

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

[0392] And it is followed by the liquid deposition on the strip optical insulating coating or on the lower interlayer (back or front) strip of a composition comprising a matrix including an organic, crosslinkable (by UV in particular, photo or thermocrosslinkable) matrix and diffusing particles layer in one or more 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 extracting composition takes place (at room temperature) before the calendering process and even before preheating.

[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 are: flexography, photogravure, inkjet printing.

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

[0398] Other details and advantageous features of the invention will become apparent from reading the examples according to the invention illustrated by the following figures.

[0399] Figure 1 shows a schematic cross-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 manufacturing steps of this illuminable laminated glass roof 100.

[0400] Figure 1 shows a schematic cross-sectional view of a 100' illuminated laminated glass roof of a motor vehicle according to the invention in a variant of the first embodiment. Figure 1 describes manufacturing steps for this 100' illuminated laminated glass roof.

[0401] Figure 2 shows a schematic cross-sectional view of an illuminable laminated glass roof 200 of a motor vehicle according to the invention in a second embodiment. Figure 2a describes a manufacturing step of this illuminable laminated glass roof 200.

[0402] Fig. 2 represents a schematic cross-sectional view of a 200' illuminateable laminated glass roof of a motor vehicle according to the invention in a variant of the second embodiment.

[0403] Figure 3 shows a schematic cross-sectional view of an illuminable laminated glass roof 300 of a motor vehicle according to the invention in a third embodiment. Figure 3a describes a manufacturing step of this illuminable laminated glass roof 300.

[0404] Fig. 3 represents a schematic cross-sectional view of a 300' illuminateable laminated glass roof of a motor vehicle according to the invention in a variant of the third embodiment.

[0405] Figure 4 shows a schematic cross-sectional view of an illuminable laminated glass roof 400 of a motor vehicle according to the invention in a fourth embodiment. Figure 4a describes a manufacturing step of this illuminable laminated glass roof 400.

[0406] Figure 5 shows a schematic cross-sectional view of an illuminable laminated glass roof 500 of a motor vehicle according to the invention in a fifth embodiment. Figure 5a describes a manufacturing step of this illuminable laminated glass roof 500 and alternative manufacturing steps in Figures 5b, 5c, 5d, and 5e.

[0407] Figure 6 shows a schematic cross-sectional view of an illuminable laminated glass roof 600 of a motor vehicle according to the invention in a sixth embodiment. Figure 6a describes a manufacturing step of this illuminable laminated glass roof 600.

[0408] Figure 7 shows a schematic cross-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 manufacturing steps of this illuminable laminated glass roof 700, and Figures 7c, 7d, 7e, and 7f are manufacturing variants.

[0409] Fig. 7 represents a schematic cross-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 process for forming the functional laminate roll in a first configuration of the invention, a roll-to-roll process with, in figures 8' and 8", variants of functional laminate according to the invention that can be obtained.

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

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

[0413] Fig. 10 represents a schematic view of a process for forming the functional laminate roll in a second configuration of the invention, a roll-to-roll process.

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

[0415] Fig. 1 represents a schematic cross-sectional view of an illuminable laminated glass roof 100 of a motor vehicle according to the invention in a first embodiment, with (in magnification) a detailed view of the prismatic reflector film used to redirect the light and a detailed view of the 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 refers to a laminated car roof 100, (generally) rectangular and domed (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 of 2.1 mm for example), with a first main face 11 corresponding to 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 face F2 coated with a low-emissivity 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 likewise shape and dimensions that 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 silicosodocalcic 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 2.9 mm, glass 2 of refractive index ni of the order of 1.52 at 600nm or even Optiwhite glass of 1.95mm or Sunmax glass of 2.05mm.

[0420] - between face F2 12 and face F3 13, a transparent lamination interlayer 3, with an edge (outside or part of it) aligned or possibly recessed from glass 1, 2, a multilayer laminated 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, grey, of TL at 27%, of 0.38mm thickness or 0.76mm (in one or two sheets possibly with an indistinguishable interface)

[0422] - a second intercalated layer, called the lower layer 32, preferably thermoplastic 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 intercalated layer, called the upper layer 33, thermoplastic, here of preferably based on plasticized PVB (at least 30% by weight plasticizers), for example 0.38mm or 0.76mm (in one or two sheets), in adhesive contact with face F2, third interlayer clear or in tinted variant, for example grey, of TL at 27%.

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

[0425] The laminated glass roof 100 has an internal masking layer 7 forming a masking frame delimiting a glass area 70 (daylight area), here (generally) rectangular, for example with straight edges. Any local modification of the edges 70 is possible (gradient of points, wider area, etc.). For example:

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

[0427] - or the internal masking layer 7 is a black ink, on one of the faces of the upper intercalated layer 33 preferably with the face oriented towards the face F2, ink preferably based on PVB with black pigments.

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

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

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

[0431] To optically isolate the lower part with light guide and light extraction from the tinted, absorbent upper part, the laminated glazing roof 100 further comprises an optical insulating layer which here comprises an optical insulating 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 layer 31 and the lower interlayer layer 32 (and even in adhesive contact), extends throughout the clear glass and preferably beyond, its edge being under the masking layer 7, preferably recessed from the glass 1,2.

[0433] To simplify and improve the reliability of manufacturing, the first interlayer 31 / optical insulator layer / lower interlayer 32 assembly (of similar dimensions) was pre-laminated (by calendering). Then, the lower interlayer 32 was partially cut, leaving a frame surface 31' extending beyond the first interlayer 31.

[0434] A thermoplastic laminate interlayer frame 34, preferably based on plasticized PVB (with at least 30% by weight of plasticizers), is on the periphery of the lower cut interlayer layer 32 (and in adhesive contact with it) and the optical insulating layer 5.5' is in adhesive contact with the frame surface 31' and the face F3 13. The optical insulating layer (and even the first film 5') is here less than 200pm thick or even at most 100pm and is protected at its 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 lenses 1, 2 in particular by at least 10mm.

[0436] The optical insulating coating 5 is made of a material, preferably a polymer, comprising a matrix, in particular distinct from a fluoropolymer, of submillimeter thickness, at least 400 nm and preferably at least 500 nm or 800 nm or 1 pm, and a layer 50 optionally recessed from the layer of the first film 5' without compromising the optical insulating function. The optical insulating coating 5 may be directly on the first film 5' or on a functional sublayer (barrier, etc.), transparent to the first film 5'. The optical insulating 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 insulating coating 5 comprises a crosslinked polymer matrix with said index n2, preferably of at most 1.42 and optionally of at least 1.35, the matrix preferably being among polyacrylate-based polymers with a fluorinated function, in particular urethane acrylate or fluorourethane acrylate or fluorosilicone acrylate. The thickness is preferably at most 1 Opm or 5 µm or 2 µm and at least 800 nm.

[0439] In one configuration, the optical insulating 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 possibly of at least 1.35), and comprising (nano)poroses and / or low-index (nano)particles (with a refractive index less than ni), in particular hollow, preferably with a size of at most 300 nm or even 100 nm, for example hollow silica nanoparticles. The thickness of the optical insulating coating is preferably at most 10 mm or 5 pm and at least 800 nm.

[0440] More broadly, the matrix can be a cross-linked polymer or thermoplastic, in particular chosen from polymers based on polyacrylate, polyepoxides, polyvinyl acetate, polyester, polyurethane, PVB, or minerals, notably silica. A polymer matrix based on polyacrylate, polyurethane, or even polyepoxides, polyvinyl acetate, or polyester is preferred.

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

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

[0443] For example, the first transparent 5' film is a clear PET with a TL of about 90% or more (or tinted and even opaque), of less than 200pm, in particular 100pm or 75pm.

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

[0445] - one or two groups of 4.4' light-emitting diodes (here front-emitting) or "top emission"), in the form of straight strips on a 40, 40' support (for example printed circuit board, known as 'PCB') opposite (or offset from) the fourth main face F4 14, and even integral with the face F4

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

[0447] For example, as shown in the detail view, each reflective prismatic film 8 comprises a polymer prismatic film, for example of thickness 125 µm, with:

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

[0449] - and a textured layer (embossing of a resin, for example cross-linked polyacrylate) for example by ultraviolet UV etc), partially or even entirely textured, forming prisms 82 which become reflectors by a reflective layer 83 for example metallic (by conformal deposition on the textured prismatic surface), here reflective prisms oriented towards face F3.

[0450] Here each prismatic reflective film 8 is in adhesive contact with the frame surface 31' (via the base 81) and with the front face of the interleaving 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 cross-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 with respect to the face F4).

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

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

[0454] The light from the diodes 4,4' is refracted in the second glass 2, in the prismatic reflector 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 F3 side) 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 insulating coating 5.

[0455] The reflective prismatic films 8 are attached to the first film 5', and even to the optical insulating coating 5, or spaced at most 4 mm apart to prevent light leakage. As a precaution to prevent stray light passing through the prismatic film 8 (particularly light or lightly tinted base) and even the masking layer 7, an optional internal opaque element is added to each prismatic film 8 (of the same width and not exceeding the inner edge 80' of the prismatic film 8).

[0456] Alternatively, one or more transparent prismatic films are chosen, with the F4 face located downstream of the diodes. The diodes 4, 4' and / or their support can be fixed to the F4 face (by an additional part, by direct bonding, etc.).

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

[0458] In particular, one can have (on each side of the viewing window) a set of diode strips on supports 40 that are either disjoint or connected to each other, preferably aligned. One can also place (alternatively or cumulatively) diode strips on the front or rear edges (on each side of the viewing window).

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

[0460] 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 has an acrylate matrix, preferably with a refractive index greater than or equal to ni, with TiO2 particles of at least 100 nm in diameter and preferably of no more than 1 pm or 400 nm. The diffusing coating is, for example, 100 pm to 100 pm or even 50 pm thick.

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

[0464] Alternatively, the diffusing coating (diffusing pattern or network of patterns, disjoint and / or interconnected) is in contact with face F3 and preferably covers no more than 40% of the clear glass area 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, oriented towards face F3. The diffusing coating 6, comprising a polymer or mineral matrix, is deposited by liquid means (by inkjet, screen printing, etc.). The diffusing coating is alternatively deposited on face F3, for example, an enamel.

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

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

[0467] A coating reflecting infrared 17 on face F4, forms a low emissivity layer (in particular a multilayer at ITO, 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, approximately 0.4 mm, another interlayer frame 35 is added, for example 0.38 mm thick, made of clear or tinted plasticized PVB. The edges of the device 9 are under the internal masking layer 7. The device 9 may or may not be the same size as 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 detail view, the variable diffusion device 9 comprises:

[0472] - a first support 91 (polymer, thermoplastic such as PET, of 125 µm for example) with a first electroconductive coating 92 (for example ITO) on the second side F2

[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 125µm for example) with a second electroconductive coating 92' (for example ITO) 92' third side face F3:

[0475] The electroconductive coatings 92, 92' at the periphery are not covered by the electroactive layer 93, and current-carrying strips 90 are placed there for power supply. In particular, the supports 91, 91' protrude on two opposite sides.

[0476] For the purpose of protecting the electroactive layer 93, a chemical protection means 94 (barrier to possible plasticizers of the PVB) can be provided, for example by ad hoc arranged PET polymer frames, in particular a Z-section frame (three portions 941, 942, 943) coupled to a rectangular section frame 944.

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

[0478] The assembly formed of the trilayer, the frame 34, the prismatic films 8,8' forms a lower block 10 in adhesive contact with an upper block comprising or formed of the electroactive device 9, the other frame 35 (identical size or distinct from the frame 34 depending on the extent of the electroactive device 9) and the upper intercalated 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 lenses 1,2 (bare or custom coated).

[0480] An example of manufacturing a self-illuminating laminated roof according to the invention first involves supplying a roll of multilayer laminated functional strip laminate, 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 manufacturing steps of the illuminable laminated roof 100 from such a roll of laminated laminate.

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

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

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

[0485] - preferably a total pre-cut (continuous) by 190 blades (in particular (controlled cutting: pressure, displacement, speed, etc.), straight cutting for simplicity, along the two free edges of the strip (or alternatively a single free edge), so that the pre-cut strip in line has a free edge formed by the free edges of the first interlayer 31, the first film 5 coated with the optical insulating coating 5' (or alternatively a fluoropolymer film), the lower interlayer 32 with preferably the light extraction layer 6 in one or more diffusing patterns

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

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

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

[0489] Step 22 illustrates the following operations:

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

[0491] - lateral straight cut along Y by blade 192 (controlled) to a length desired (predetermined) of the functional three-layer laminate.

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

[0493] - with a blade 193, a circumferential and partial cut of the trilayer 31,5,5',32, which is a total cut on a thickness E' of the first coated film 5, and of the lower interlayer 32, called the cut layer, leaving a frame surface 31' protruding from the first interlayer 31 preferably of width W1 of at least 20mm (and preferably of no more than 200mm or 100mm), called the full layer.

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

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

[0496] Preferably, an automatic cutting system is used, itself composed of a mounting table, possibly a conveyor belt, the blade supported in an orientable tool which is itself attached to 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 path. For example, a blade moves along the X-axis of a bar and the bar moves along the Y-axis of the conveyor belt

[0498] Preferably, to hold the element to be cut, suction is applied by means of holes in the carpet.

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

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

[0501] The fifth step 205 involves the formation of the lower manipulable block 110 comprising the trilayer and, joined by local bonds to the trilayer, the intercalated frame 34 and the two prismatic reflective films 8,8' along opposite edges here longitudinal edges of the trilayer (of general quadrilateral shape similar to the general shape of the lenses 1,2, longitudinal edges parallel or not and / or lateral edges parallel or not).

[0502] Local bonding (adhesive contact) consists in particular of spot welds 195, achieved by (local) softening of an interlayer material, preferably PVB (of the frame 34 and / or the three-layer material). Bonding is preferably achieved by local heating and possibly also by pressure. This bonding method is preferred to gluing by adding adhesive (glue bead or double-sided tape).

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

[0504] With a soldering iron the temperature can be 250°C, the solders are fast and deep (possibly melting the entire thickness of the interlayer material, of PVB), without pressure required.

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

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

[0507] For the bonding of the intermediate frame 34 / trilayer, the contact areas for the local bonds can be centered a few mm from the boundary between the frame and the trilayer (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 (distributed regularly or not) are made around the entire perimeter of the intermediate frame 34 / lower intermediate layer 32.

[0509] The bonding of the 34-layer interlayer frame can be done in a single operation for all local bonds. A heating tool can be chosen that allows the various point adhesives to be applied in a single operation, for example, using heated fingers.

[0510] For example, 10 mm heating fingers are on the lower intermediate layer 32 (rear face) and the intermediate frame 34 (rear face), centered alternately 5 mm from the boundary on the lower intermediate layer 32 and 5 mm from the boundary on the frame. The centering of the local melt (of the heating fingers) is schematically represented by circles in [Fig. 1a].

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

[0512] The prismatic films 8,8' are bonded together 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 includes an assembly step comprising:

[0514] - a placement (and centering) on ​​the second sheet of glass 2, called sheet of reference of the complete block 120 (lower block 110 integral with the upper block 111 as detailed in the cross-section view subsequently in [Fig.lb])

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

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

[0517] - a possible local solidification complete block 120 / first sheet 1, by heating local as above (multi-point welding), of the intercalated material (adhesive contact)

[0518] - the puff pastry.

[0519] The puff pastry preferably comprises:

[0520] - a vacuum sealing (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 minutes,

[0521] - heating at a temperature ranging from 80°C to 120°C for a period of 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 prismatic reflective films 8', 8 are protected, encapsulated by lamination interlayer material (here PVB) by lamination (of the first interlayer sheet 31 etc).

[0523] In particular in a first configuration for managing the edges of the interleaving strip: - The complete block 120 is dimensioned 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 deburring (trimming in English) of 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 interlayer edge management configuration, the complete block 120 is dimensioned and positioned so that the edges of the interlayer frame 34 and the other frame 35 and the interlayer layers 31,33 have a setback of 0 to 4mm relative to the edges 10,20 of the glass sheets 1, in which case there is no need for 'trimming' and 'brushing'.

[0525] Fig. 1b illustrates in cross-section the main manufacturing steps of the 100 laminated self-roof with various cutting operations and local bonding.

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

[0527] The second placement step 102 comprises:

[0528] -a placement of the 8.8' prismatic reflective films on the 31' frame surface and along the longitudinal edges of the cut part of the trilayer, ensuring that the 8.8' prismatic reflective films are less than 4mm and preferably 1mm from the edge of the first film 5 (or even attached to the edge of the first film 5).

[0529] The prismatic reflective films are preferably of equal width 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 lenses 1,2.

[0530] The third step 103 of solidarity comprises: - a local bonding 195 of the prismatic reflective films 8.8' to the frame surface 31' (for example two points of welding, by local softening of the frame surface (local heating, by heating fingers, as mentioned above etc).

[0531] The fourth step 104 of the formation of the lower block 110 (corresponding to step 205 in top view in [Fig.1a], described herein in more detail) comprises in this order:

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

[0533] - a local solidarity 195 of the intermediate frame 34 to the surface frame 31', for example in multipoint, by local softening of the intermediate frame 34 and of the frame surface 31' (local heating, by heating fingers, as above etc), in particular the intermediate frame 34 is edge to edge with the first intermediate layer 31 (or with overhang or retraction 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] - a placement of the 8.8' prismatic reflective films (less than 4mm and better 1mm from the edge of the first film 5 or even attached) then following the interleaved frame 34 on the frame surface 31'

[0536] -and a single local bonding operation of the reflective prismatic films and the interlayer frame 34 with the trilayer, by local softening (local heating, by heating fingers as above etc), for example multi-point welding in one operation.

[0537] In the 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 intercalated frame 34 (at less than 4mm and better 1mm from the edge of the first film 5 or even attached),

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

[0540] -a placement of the intercalated frame 34 integral with the prismatic reflective films 8.8' on the frame surface 31',

[0541] - a local solidarity of prismatic reflective films linked to the frame interlayer 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 to, independent of, the fourth step 104) of forming the upper block 111 with an electroactive system 9 (here with liquid crystals) comprises:

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

[0544] - if peripheral protection is required: placement of the first protective frame in Z 94 (in three sections 941, 942 and 943) on the inner perimeter 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 (around the entire perimeter) in one operation

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

[0546] - if peripheral protection is required: 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 whole perimeter) in one operation.

[0547] We can also 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 made by folding etc. A protective material can also be used (by liquid deposition etc.).

[0549] In another variant, the electroactive element 9 includes an internal peripheral protection, optionally an internal polymer seal between the two electroconductive films 91,91' (on the periphery of the element 93).

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

[0551] As an alternative to this step 104', on the third intercalated layer 33, called upper (PVB sheet), the electroactive element 9 before the other interleaving frame 35

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

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

[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 9 with the other intermediate frame 35 locally attached to the third intermediate layer 33 and comprising the protective frames all around (frame 94 with Z-shaped cross-section 941, 942 and 943 and frame with rectangular cross-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 bonding of the first intercalated layer 31 with the other intermediate frame 35 (local heating, with heating fingers, multipoint welding, as already mentioned etc) to form the complete block 120 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 intercalated layer 33 (in its central part, no local bonds).

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

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

[0560] - an installation (with centering) on ​​the second sheet of glass 2, called sheet of reference of the complete block 120 (with the lower block 110 attached to the upper block 111), the lower block being in contact with face F3 13

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

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

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

[0564] The puff pastry is then made.

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

[0566] The 1.2 glass sheets are clean.

[0567] The complete block 120 may further include peripheral connectors (extending from the glass sheets 1,2, and between the two glass sheets 1,2) for example to electrically supply the electroactive element 9.

[0568] Fig. 1 represents a schematic cross-sectional view of a 100' illuminateable laminated glass roof 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 double-layered PVB interlayer frame 34, 341, 342 (still forming part of the lower block 110'). The electroactive element 9 is here more extensive than the first film 5'. The opposite is also possible.

[0570] The upper sheet 341 on the side of the first interlayer 31 may be opaque, the lower sheet 342 is clear. For example, each sheet 341, 342 is of a thickness (identical or different) of at least 0.3 mm and made of plasticized PVB (standard).

[0571] The manufacture of the complete 120' block is quite similar to that described for the complete 120' block of [Fig. 1]. Only the differences are detailed in relation to [Fig. 1]'a illustrating in cross-sectional view the manufacturing steps of the 100' illuminated laminated roof.

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

[0573] - a pre-assembly 195 of the reflecting prisms 8, 8' with the two frame sheets of upper (usual) PVB 341 and lower 342 by local softening of the interlayer frame 34 (local heating, with heating fingers for example, especially on two contact areas, in one operation)

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

[0575] This is followed by a third step 103 involving the joining 195 of the multi-layer frame 34 with reflector prisms 8.8' to the first interlayer layer 31, by local softening of the interlayer frame 34 and of the first interlayer layer (local heating, in particular with heating fingers all around, 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 layer 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 face F2.

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

[0579] Fig. 2 represents a schematic cross-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 reflective prisms 82, 83 of the reflective 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 overlay 51 (protective etc.), transparent, is inserted between the optical insulating 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.laa], some manufacturing steps are detailed in relation to [Fig.2a].

[0584] After the first circumferential and partial cutting step 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 prismatic reflective films 8, 8' (reflective 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 195 bonding of the intermediate frame 34 with the first intermediate layer 31 and even of the lower intercalated layer 32 by local softening of intercalated material -intercalated frame 34; first intercalated layer 31, lower intercalated layer 32- (local heating, with heating fingers for example, on multiple contact areas.) and a bonding 195 of the reflecting prisms with the intercalated frame 34, by local softening of the intercalated frame 34 (local heating, with heating fingers for example, on multiple contact areas.).

[0589] Alternatively, step 102 second comprises:

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

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

[0592] And a third step 103 comprises:

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

[0594] - a 195 solidification of the reflecting prisms with the intercalated frame 34, by local softening of the interlayer frame 34 (local heating, with heated fingers for example, on multiple contact areas) and of the first interlayer layer 31.

[0595] The next step in forming the complete block 220, not shown, is similar to the fifth step 105 already described. The next step in placing the block 220 for lamination, also not shown, is like the sixth step 106 already described.

[0596] Fig. 2 represents a schematic cross-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 second mode 200 roof in that:

[0598] -8, 8' films are transparent prismatic films (monolithic or with a base covered with a textured layer, for example resin, embossed etc), without a reflective layer, spaced or attached to the F4 14 face and even here glued (by an optical glue 6') to the F4 14 face, so 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 all or part opposite the first film 5' (preferably remaining under the masking layer 7)

[0599] - possibly the lower interlayer 32' is a plasticizer-free PVB (or with less than 10% or 5% plasticizer) for example 30µm or 50µm thick - and carrying here on the back side the light extraction layer in one or more diffusing patterns 6 (or alternatively on the front side),

[0600] - possibly the absence of layer 17

[0601] Alternatively the light extraction layer is facing F3 or F4, 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 section cut out 32.5.5',

[0605] - the placement of the intermediate frame 34 on the protruding frame surface 31', then local bonding, by softening of intercalated 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 securing local by softening of intercalated 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 we can remove the intermediate frame 34. The protection is done by creep of the PVB 31.

[0609] Alternatively, the upper block is removed.

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

[0611] The upper block is optional.

[0612] Fig. 3 represents a schematic cross-sectional view of an illuminable laminated glass roof 300 of a motor vehicle according to the invention in a third embodiment.

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

[0614] - the optical insulating layer is formed by a 5” fluoropolymer film (corona treated) for example, 50mm thick

[0615] - possibly the lower interlayer 32' is a plasticizer-free PVB (or with less than 10% or 5% plasticizer) for example 30µm or 50µm thick - and carrying here on the back side the light extraction layer in one or more diffusing patterns 6 (or alternatively on the front side),

[0616] - by the absence of an intercalated 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 trilayer, total cutting of the 5” fluoropolymer film and the 32' lower interlayer, PVB, leaving the 31' frame surface protruding and a 32'.5" cut-out portion.

[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', (reflective 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) in forming the complete block 320 (ready for assembly) comprises:

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

[0623] - a local bonding of the first intercalated layer 31 with the other frame spacer 35 (local heating, with heating fingers, multipoint 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 cross-sectional view of a 300' illuminateable laminated glass roof 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 insulating layer is formed by the first PET film 5' for example of thickness lOOpm and the optical insulating coating 5 (for example as in the first mode 100), - Due to the absence of the upper block, the first intercalated layer 31 is in contact with the solar control layer 18 (optional) and the masking frame 7 - possibly a single prismatic reflective film 8 (and a single diode strip 4) for example on a longitudinal edge or on a lateral edge (front or rear).

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

[0628] The next assembly step for lamination comprises:

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

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

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

[0632] - a possible local bonding of the first intercalated layer 31 with the first sheet 1 (local heating, multipoint welding).

[0633] The puff pastry is then made.

[0634] Alternatively, the electroactive element 9 is for example laminated by calendering, for example an all-solid electrochrome, preferably of thickness <200pm and even of at most 150pm, without the need for another interlayer frame 35 so that the laminated laminate also includes in addition to the trilayer (and before the partial cutting of the laminate 101) - the third interlayer layer 33 - the electroactive element 9, set back from the edges of the third interlayer layer 33 and the first interlayer layer 31, encapsulated, protected by these sheets.

[0635] Fig. 4 represents a schematic cross-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, always under the masking frame 7, and against or glued to the face F3 13

[0638] - two opaque 7' strips (coating, black for example, on the first film of (preferably on the rear face) are opposite the prismatic films 8, 8' in case 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 of thickness from 50pm to 200pm) 9' carrying the solar control electroconductive coating 18 on front face (the film may 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 solar control function film 9'.

[0640] The electroconductive coating thus offset from the bare face F2 (or which may have a custom-made functional coating), one can also have a composite functional film without an electroconductive coating

[0641] The 420 laminate is a multilayer laminate which, in addition to the trilayer 32, 5' (with its coating 5), 31, and the interlayer frame 34 around the perimeter of the trilayer, comprises the solar control film 9' (with its coating 18) and the third interlayer 33 (upper). If necessary, the multilayer laminate includes two opaque bands 7' (coating, black for example, on the first film, preferably on the back side) opposite the prismatic films 8, 8' in case of stray light (passing through the films 8, 8').

[0642] Alternatively, the 90' ​​edges are aligned with the edge of the trilayer and even the interlayer frame 34 (thicker) extends to face F2 12. For example, a total cut of the multilayer has been made with the frame 34 around the perimeter.

[0643] Regarding the manufacture of the roof 400 illustrated in part in [Fig.4a], the first step 101 of partial cutting 193 of the laminate over a thickness E', is as already described previously (the multilayer is just thicker).

[0644] This is followed by a second step 102 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 intercalated layer 32, (opposite the opaque bands 7')

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

[0647] - a 195 solidification of the prismatic reflective films 8, 8' by softening local heating of the lower intercalated layer 32 (local heating, for example with heating fingers on two contact areas, in one operation)

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

[0649] - a bonding of the intermediate frame 34 by local softening of the layer lower spacer 32 and of the spacer 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 intercalated frame 34 and its local securing, placement of the prismatic reflective films 8,8' and their local securing.

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

[0652] Figure 5 represents a schematic cross-sectional view of a laminated glass roof illuminable 500 of 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 intercalated layer 32 is whole

[0655] - the first intercalated layer 31 is shorter than the intercalated layer lower 32 (recessed 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 of width W1 of at least 20mm and for example of at most 100mm or 50mm.

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

[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 trilayer by blade 193 leaving the frame surface 321 protruding and a cut part 31,5,5' of the trilayer.

[0661] The second placement step 102 comprises:

[0662] - a placement of the prismatic reflective films 8, 8' on the frame surface 321 and along the longitudinal edges of the cut part of the trilayer. less than 4mm and preferably 1mm from the edge of the first film 5 or even abutted).

[0663] The third step 103 of solidarity comprises: - a local bonding 195 of the prismatic reflective films 8.8' to the frame surface 321 (by local softening of the frame surface 321, by local heating, for example two weld points,) - the placement of the interlayer frame 34 on the prismatic reflective films 8.8' and the frame surface 321.

[0664] The fourth step 104 of solidarity comprises: - a local bonding 195 of the intermediate frame 34 to the frame surface 321 by local softening of the frame surface 320 (for example on the whole perimeter, by local heating, by multi-point welding, by heating fingers).

[0665] The fifth step 105 of the formation of the complete block 520 comprises:

[0666] - the successive placement of the protective film 944, of the electroactive element 9, of the protective film 94, of the other interlayer frame 35, of the third interlayer layer 33 (upper) - the local bonding of the whole 944, 94, 35 by local softening of intercalary material of the other intercalary frame 35, of the intercalary frame 34, of the third intercalary layer 33.

[0667] Alternatively, the protective film 944 can be placed and secured, the electroactive element 9 can be placed, the protective film in Z 94 can be placed, the other interlayer frame 35 can be placed and secured with the interlayer frame 34 and the protective films 94 and 944, the third interlayer layer 33 can be placed and secured with the other interlayer frame 35.

[0668] 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.

[0669] In another configuration (see [Fig. 5b]) the fifth step 105 of the formation of the complete block 520 (ready for assembly) comprises:

[0670] - a placement of the lower block 510 on the upper block 111 (front face of the frame interleaving layer 34 and the first interleaving layer 31 on the back face of element 9 and the other interleaving frame 35, -and also on protective film 94)

[0671] - (not shown) a local solidarity of the intermediate framework 34 with the other Interlayer frame 35. (local heating, with heating fingers, multi-point welding)

[0672] 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 intercalated layer 32', a PVB with little or no plasticizer; thin; bearing on its back face the diffusing pattern(s) 6 - and / or one or more reflective prisms 8, 8' in a multi-layered frame 341,342 for example on two opposite edges.

[0673] The upper sheet 341 on the side of the first interlayer 31 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 (standard).

[0674] As shown in [Fig. 5c], the formation of this lower block 510' comprises, in this order (after partial cutting of the trilayer):

[0675] - a pre-assembly 195 of the reflecting prisms 8, 8' with two frame sheets of PVB 341, 342 by local softening of the interlayer frame 34 (local heating, with heating fingers for example on two contact areas, in one operation)

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

[0677] - a third step 103 involving the joining of the multi-layered frame 34 to prisms on the lower intercalated layer 32' (entire), by local softening of the intercalated frame 34 and the lower intercalated layer 32' (local heating, with heating fingers, all around, in one operation).

[0678] Performing the partial cut on the first interlayer 31 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 insulating layer 5 having similar dimensions and thus to reduce the operations.

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

[0680] - successive placement:

[0681] -of the thick 34' frame on the 321 surface (already with the 8.8' prismatic films possibly),

[0682] -of the 94 Z-shaped protective film 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) - the local bonding of the whole by local softening of intercalated material (local heating), of the intercalated frame 34', of the lower intercalated layer 32, of the third intercalated layer 33.

[0686] Alternatively, one can place and secure the intermediate frame 34' with the lower intermediate layer 32, place the protective film in Z 94, place element 9, and secure it with the intermediate frame 34 and films 94 and 944, place the third intermediate layer 33 and secure it with the intermediate frame 34' (local heating).

[0687] Alternatively, one can place and secure the interlayer frame 34' already carrying the prismatic films (on the surface or in a multi-layer) with the lower interlayer layer 32, place the protective film in Z 94, place element 9, secure films 94 and 944 with the interlayer frame 34, place the third interlayer layer 33 and secure it with the interlayer frame 34'.

[0688] The electroactive element 9 can already be protected for example by a PET frame film of C cross-section instead of 94 and 944. Optionally the lower interlayer is a PVB without plasticizer for example of 30pm, carrying the diffusing coating on the back (or front) face.

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

[0690] - successive placement:

[0691] - 8.8' prismatic reflective films on the 321 frame surface, prismatic films reflectors of equal width to that of the frame surface or preferably even recessed by at least 5mm, ensuring that the 8.8" prismatic reflector films are less than 4mm and preferably 1mm from the edge of the 5" film (or even directly against the edge of the 5" film)

[0692] -of the thick frame 34', on the prismatic reflective films 8.8' and the frame surface 321

[0693] -of the protected electroactive element 9,

[0694] -of the third intercalated layer 33 on element 9 and frame 34' - of the local bonding of the whole by local softening (local heating) of intercalated material (of the intercalated frame 34', of the lower intercalated layer 32', of the third intercalated layer 33).

[0695] Alternatively, one can place and secure the intercalated frame 34' already carrying the prismatic films (on the surface or in a multi-layer) with 32, place element 9, place the third intercalated layer 33 and secure it with the intercalated frame 34'.

[0696] Fig. 6 represents a schematic cross-sectional view of an illuminable laminated glass roof 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, of at least 0.3mm)

[0699] - by the absence of an intercalated frame around the perimeter of the optical insulating layer (first film 5' and coating 5 or fluoropolymer film as an alternative), 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 intercalated layers 31, 32 (to the dimensions of the lenses 1, 2 and even according to the shape of the lenses), the optical insulating layer being intact

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

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

[0703] The following (not shown) is the formation of the complete block 620:

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

[0705] - (not shown) bonding of blocks by local heating through softening of the first intercalated layer 31 and the other intercalated frame 35, of the lower intercalated layer 32.

[0706] The next assembly step for lamination comprises:

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

[0708] - a possible local solidarity block complete / second sheet 2, by softening (local heating) of the first interlayer 31, of the other interlayer frame 35, of the lower interlayer layer 32 (multi-point weld)

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

[0710] - a possible local bonding of the third intercalated layer 33 / first sheet 1 (local heating, multi-point welding)

[0711] The puff pastry is then made.

[0712] Alternatively, the electroactive element 9 is for example laminated by calendering, for example an all-solid electrochrome, of thickness of at most 200 µm, without the need for another interlayer frame 35 so that the laminated laminate also includes in addition to the trilayer (and before the possible marginal cutting)

[0713] Fig. 7 represents a schematic cross-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 of the lower block 210

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

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

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

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

[0720] The third step 203 comprises:

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

[0722] The fourth step 204 comprises:

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

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

[0725] The fifth step 205 involves the formation of the manipulable lower block 710 comprising the trilayer and, attached by local bonds to the trilayer, the interlayer 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 bonding methods include spot welds 195, achieved by (local) softening of the interlayer material (of the frame and / or the three-layer material). Bonding is achieved through local heating and possibly also by pressure. This method is preferred to bonding with a bead of glue or double-sided adhesive.

[0727] The temperature and pressure are adjusted according to the intercalated material and the tool, in particular heated fingers or a soldering iron

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

[0729] For the bonding of the intermediate frame 34 / trilayer, the contact areas for the local bonds can be centered a few mm from the boundary between the intermediate frame 34 and the trilayer (which is a junction or an inter-slope 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 bonding of the 34-layer interlayer frame can be done in a single operation for all local bonds. A heating tool can be chosen that allows the various point adhesives to be applied in a single operation, for example, using heated fingers.

[0732] For example, 10 mm heating fingers are on the lower interlayer 32 (rear face) and the interlayer frame 34 (rear face), centered alternately 5 mm from the boundary on the lower interlayer 32 and 5 mm from the boundary on the frame. The centering of the heating fingers is shown by circles in [Fig. 7a].

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

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

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

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

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

[0738] - a possible local solidarity (local heating), third intervening layer 33 / first sheet 1.

[0739] The puff pastry then consists of:

[0740] - a vacuum sealing (to evacuate the air present between the two sheets of glass, by suction etc., at cold, ambient temperature) for a period of 15 to 45 minutes,

[0741] - heating at a temperature of 80°C to 120°C for a period of 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 prismatic reflective films 8', 8 are protected, encapsulated by lamination interlayer material (PVB here).

[0743] Fig. 7b illustrates in cross-sectional view the main manufacturing steps of the 700 laminated self-roofing with various cutting operations and local bonding.

[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 intercalated 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 34 interlayer frame close to the inner edge of the interleaving frame 34 (to be less than 4mm and better 1mm from the edge of the first film 5 or even adjacent)

[0748] - a local pre-bonding of the 8.8' prismatic reflective films on the frame 34 (rear face of the intermediate frame 34) by local softening of the frame (local heating, by heating fingers etc.),

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

[0750] An alternative manufacturing method for 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 face F3

[0754] - a placement of the interlayer frame 34 on the 8.8' prismatic reflector films close to the inner edge of the 34 frame (to be less than 4mm and better 1mm from the edge of the first 5 film or even adjacent)

[0755] - a local pre-bonding of the 8, 8' reflective prismatic films on the frame 34 (rear face of the intermediate frame 34) by local softening of the frame (local heating, by heating fingers etc.),

[0756] - the placement of the cut trilayer in frame 34

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

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

[0759] An alternative manufacturing method for 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 frame 34 then of the three-layer cut out within framework 34, local solidarity

[0761] - a placement of the prismatic reflective films 8, 8' on the intercalated frame 34 close to the inner edge of the 34 frame (to be less than 4mm and better 1mm from the edge of the first 5 film or even right next to it)

[0762] - a local solidarity of the prismatic reflective films 8, 8' on the frame (face before 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 predict:

[0765] - on face F2 of the first sheet 1, placement of frame 34 with the films prismatic reflectors 8.8' pre-bonded (by local heating, by heating fingers etc) then of the trilayer 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 manufacturing method for 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 multi-sheet frame 34 341,342 housing the pre-bonded 8.8' prismatic reflective films and then the cut tri-layer within the 34 frame, local bonding.

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

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

[0771] A step 102 (after total cutting of the trilayer) is the placement on the rear face of the lower interlayer 32 of the reflective prismatic films 8, 8' and their bonding by local bonding (local heating).

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

[0773] Fig. 7 represents a schematic cross-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 reflective 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 tinted glass.

[0775] The manufacture of the complete block 720' is quite similar to that described for the complete block 720 of [Fig.1].

[0776] It is preferable that the prismatic films not be in the laminated by calender but added after calendering, because there is a risk of damaging them.

[0777] Fig. 8 represents a schematic view of a process for forming the functional strip laminate roll 212 in a first configuration, roll-to-roll process, with figures 8' and 8" showing laminate variants according to the invention that can be obtained by this process.

[0778] The process for forming the functional laminate roll 1001 comprises:

[0779] - from the unwinding of a roll called the first interleaf unwinding roll 2002 comprising the first interlayer (sheet) 31 in strip form, preferably made of thermoplastic material such as PVB (clear or tinted) with preferably at least 20% plasticizer, of a thickness of at least 0.3 mm, possibly multi-layered (acoustic PVB), a first continuous printing of the first interlayer (sheet) 31, in strip form, having principal faces for example of roughness defined by an Rz parameter of at least 50 µm, and preferably with 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 thermoplastic film 5 coated with an optical insulating coating 5' (optionally with a protective overlayer) bonded (pre-laminated, in adhesive contact with) the lower interlayer 32' (clear) which is based on thermoplastic material such as PVB with preferably at most 5% or 1% or 0% plasticizer, preferably with a thickness Ei of at most 80µm and even at most 50µm or 35µm, having a main bonding face 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 a roughness Rz defined by a parameter of at most 50µm, a second continuous printing of the bilayer, in strip, preferably with a guide roller 2011

[0781] - heating the first intercalated layer 31 in a strip, by means of IR 1111 resistors close to the band

[0782] - near the heating element, the formation of the laminated material by calendering 2111 in this order of the first heated interlayer 31, the bilayer with diffusing patterns 6 in contact with a calendering roller, in particular rubber

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

[0784] - if necessary the insertion of a temporary protective polymer film 36 (anti adherent) 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] — the rolling of the laminated laminate onto the roller called the winder 1001.

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

[0787] To improve the reliability of the unwinding, inflatable 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, particularly if in adhesive contact with 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 coat with sufficient hardness (at least 1H) to be in contact with the calender. The diffusing coating 6, consisting of one or more diffusing patterns 6, preferably has a coverage rate of no more than 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 depositing a PVB-based resin in liquid form onto the first film 5' (preferably on the back side of the optical insulating coating 5 rather than the front side). Then the diffusing coating is applied in liquid form, for example by printing (inkjet, roller, etc.).

[0793] This can also be done in variations:

[0794] -a strip laminate with the diffusing coating 6 between the optical insulating coating 5 (optionally protected) and the rear face of the lower interlayer layer 32 (preferably a diffusing coating deposited by liquid on the rear face or on the optical insulating coating 5 (optionally protected)

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

[0796] - a strip laminate 214 (see [Fig.8]”) with the diffusing coating 6 between the optical insulating coating 5 (optionally protected) and the rear face of the lower interlayer 32 which is preferably made of ordinary plasticized PVB of at least 0.3mm (preferably a liquid-deposited diffusing coating on the optical insulating coating 5).

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

[0798] This process includes:

[0799] - from the unwinding of a primitive roll 3001 comprising the first film thermoplastic 5' and the optical insulating coating 5 in strip, an initial 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 insulating coating 5 of a so-called extracting composition comprising a transparent (organic) matrix and diffusing particles, in one or more patterns, to form the light extraction layer, during said initial printing

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

[0802] The roll can be unrolled as is for the second printing (used in a mode related to the following [Fig. 10]) the lower intercalary layer 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 film thermoplastic 5 in strip, a primitive print 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 insulating coating, during said initial printing,

[0806] - liquid deposition, here for example by printing via ink roller 3002 on the optical insulating coating of a so-called extracting composition comprising a matrix and diffusing particles, forming in one or more patterns, to form the light extraction layer, particularly during the initial printing or during subsequent printing

[0807] - a possible winding of the first film with the optical insulating coating and the light extraction layer in a winding roller, roll-out for the second print.

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

[0809] It differed from the previous process in that the deposition of the so-called extracting composition is by inkjet 3012.

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

[0811] The process 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 form, preferably made of 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-layered (acoustic PVB), a first continuous drawing of the first interlayer (sheet) in strip form, having principal faces, for example, with a roughness defined by an Rz parameter of at least 50 µm, and preferably with three guide rollers 2012, 2022, 2032,

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

[0814] - from the unwinding of a roller called the lower interleaf unwinding roller 2003 comprising the lower intercalated layer 32 preferably which is based of PVB (sheet) laminated with at least 20% plasticizer and preferably with a thickness Ei of at least 0.3 mm, a third continuous print separate from the first and second prints, having for example a smooth main back face with a roughness defined by a parameter Rz of no more than 50 µm, print preferably with guide rollers 2013, 2023, 2033

[0815] - heating the first intercalated layer 31 in a strip, by means of IR 1111 resistors close to the band

[0816] - possibly a heating of the lower intercalated layer 32 in a strip, average of IR 1112 resistances close to the band

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

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

[0819] - if necessary the insertion of a temporary protective polymer film 36 (anti adherent) 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] — the rolling of the laminated laminate 215 onto the roller called the winder 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 can be a hard coat with sufficient hardness (at least 1H) to be in contact with the calender. The diffusing coating, consisting of one or more diffusing patterns 6, preferably has a coverage rate of no more than 30%.

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

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

[0825] - from the unwinding of a roll called the first interleaf unwinding roll 2002 comprising the first interlayer (sheet) 31 in strip form, preferably made of 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-layered (acoustic PVB), a first continuous printing of the first interlayer (sheet) in strip form, having principal faces for example, roughness defined by an Rz parameter of at least 50 µm, and preferably with three guide rollers 2012, 2022, 2032,

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

[0827] - from the unwinding of a roll called the lower interleaf unwinding roll 2003' comprising the lower interlayer 32 preferably being based on a thermoplastic material such as PVB with at most 5% or 1% or 0% plasticizer, preferably of thickness Ei of at most 80µm and even at most 50µm or 35µm, having a principal bonding face 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 50µm (here the bonding face), a third continuous printing separate from the first and second printings, printing preferably with guide rollers 2013, 2023, 2033

[0828] - heating the first intercalated layer 31 in a strip, by means of IR 1111 resistors close to the band

[0829] - heating the lower interlayer layer 32 in a strip, by means of resistances IR 1111 close to the band

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

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

[0832] - if necessary the insertion of a temporary protective polymer film 36 (anti adherent) 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 rolling of the laminated laminate 216 onto the roller called the winder 1001'.

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

[0835] The diffusing coating 6 can be a hard coat with sufficient hardness (at least 1H) to be in contact with the calender. The coating, consisting of one or more diffusing patterns 6, preferably has a coverage rate of no more than 30%.

[0836] Alternatively, we can do:

[0837] - a strip laminate 217 (see [Fig. 1 1]') with the first film being fluoropolymer 5” especially corona treated (for example FEP especially of 50pm) from roll 2001”, with the diffusing coating 6 on the lower interlayer 32' (preferably diffusing coating by liquid deposition) for example here on the face opposite to the bonding face,

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

Claims

1. Demands Method for manufacturing an illuminated laminated glass roof for vehicles, particularly road vehicles (100 to 710), comprising a curved, transparent laminated glass pane including: - a first transparent sheet (1), made of mineral glass, with a first main face Fl (11), a second opposing main face F2 (12), intended to form the outer glass, - a transparent polymer laminate interlayer (3, 31, 32, 33), comprising a first thermoplastic interlayer layer (31); and a second thermoplastic interlayer layer (32), referred to as the lower interlayer layer, - a second transparent sheet (2), made of mineral glass or polymer, with a third principal face F3 (13), a fourth principal face F4 opposite (14), with a refractive index of 0 in the visible - an optical insulating 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 face F3, the light extraction layer being in contact with the lower interlayer and between the optical insulator layer (5) and face F3, the process comprising in this order: - an assembly step comprising: - the placement, on one of the first and second sheets (the reference sheet), of the first interlayer layer and the lower interlayer layer - a positioning of the other of the first and second sheets, called the other sheet, - a puff pastry characterized in that the assembly step involves placing a functional laminate on the reference sheet, including a laminated three-layer structure comprising, in this order: - the first interlayer layer (31), preferably with a thickness El of at least 0.3mm - said optical insulating layer which comprises or is supported by a first thermoplastic polymer film (5', 5"), transparent, of thickness Ep preferably of at least 20pm and at most 200pm - the lower interlayer layer (32) of thickness Ei preferably of at least 20pm and in that the trilayer incorporates the light extraction layer.

2. A 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 bonding (195) of a thermoplastic laminate interlayer frame (34) with the three-layer, bonding forming local connections by local softening of the laminate interlayer material, preferably by local heating; preferably the method comprises placing on the reference sheet of the three-layer with said interlayer frame bonded to the three-layer.

3. A method for manufacturing an illuminable laminated glass roof for a vehicle according to any one of the preceding claims, characterized in that it comprises a partial peripheral cut of the trilayer (203, 101), which is a total cut over a thickness E' of the first film and of one of the first interlayer and lower interlayer, referred to as the cut layer, leaving a frame surface (31, 321) protruding from the other of the first interlayer and lower interlayer, referred to as the full layer, and in that preferably when E'>200pm, the method comprises the placement of an interlayer laminate frame on the protruding frame surface.

4. A method for manufacturing an illuminable laminated glass roof for a vehicle according to any 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 having a textured main face with reflective prisms (82, 83) and an opposite main face, referred to as the smooth face, - a further bonding of said light redirection element, preferably of thickness Er<200 µm, to the trilayer, this further bonding forming local bond(s) by local softening 76 of the interlayer material of the trilayer, preferably by local heating, - and / or a pre-bonding of said light redirection element, with an interlayer laminate frame, pre-bonding forming local bond(s) by local softening of the interlayer laminate frame, preferably by local heating and in that, preferably, the other bonding and / or pre-bonding is before placement on the reference sheet, or even before placement on an additional functional element (9).

5. A method for manufacturing an illuminable laminated glass roof for a vehicle according to the preceding claim, characterized in that the light redirection element is a reflective prismatic film having a textured main face with reflective prisms and an opposite main face referred to as the smooth face, the film preferably having a thickness Er <200|am, with the textured face oriented towards the first interlayer (31), the reflective prismatic film is positioned to be opposite, adjacent to, or offset by no more than 4 mm from the first film a) before the other bonding with the trilayer, a contact of said reflective prismatic film on a rear main face of the lower interlayer, the rear main face intended to be oriented towards face F3, the reflective prismatic film is preferably positioned to be at least partially opposite the first film b) or, before or simultaneously with the bonding with the trilayer,the pre-bonding of the prismatic reflector film - with a main face of an interlayer laminate frame, - or within an interlayer laminate frame.

6. A 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 having a textured main face with reflective prisms and an opposite main face, referred to as the smooth face, the reflective prismatic film preferably having a thickness Er<200 µm and even at least 70 µm, and comprising placing the reflective prisms: -on a surface extending beyond the trilayer, after partial cutting of the trilayer, -or on a main face of an interlayer frame of the laminate. -or within an intermediate laminated frame, the thickness of the interlayer material receiving the reflecting prisms being preferably at least 25pm, the reflective prismatic film is preferably positioned to be adjacent to or offset by no more than 4mm from the first film.

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

8. A method for manufacturing an illuminated laminated glass roof for a vehicle according to any 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 of a thickness of at least 0.3 mm

9. - placement on the third intercalated layer, preferably in this order: - of an intermediate layer of lamination (34') -an additional functional element, which is an electroactive element, particularly one based on liquid crystals, electrochromic or photovoltaic, or another functional polymer film, - laminated material on the additional functional element placement such that the interlayer frame of the laminate is both on the perimeter of the additional functional element and of the laminated laminate, - a bonding of said intercalary frame with the laminated laminate and the third intercalary layer, preferably bonding forming local bonds by local softening of intercalary material, by local heating. Method for manufacturing an illuminable laminated glass roof for a vehicle (100 to 00) according to any 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 prismatic reflector film with a textured main face and an opposite main face said to be smooth on the third face, and of an interlayer lamination frame (34) - preferably a bonding of the interlayer frame (34) with the third face (13) by local bonding, in particular by local softening of the interlayer material, preferably by local heating - the placement of the functional laminate with the lower interlayer on the third face so that the interlayer frame is on the perimeter of the laminate - preferably, the functional laminate is bonded to the third face and even to the intercalated frame by local bonding, in particular local bonding by local softening of the intercalated material, preferably by local heating - the placement of the first sheet (1) on the functional laminate and the intercalated frame.

10. A functional laminate, not more than 8 mm thick, comprising a multilayer assembly characterized in that it includes a laminated three-layer component comprising, in this order: - a first interlayer of thermoplastic laminate (31), preferably of thickness El of at least 0.3mm - an optical insulating layer (5, 5”) which comprises or is supported by a first polymeric, thermoplastic film (5') of thickness Ep preferably of at least 20 µm and at most 200 µm - a second interlayer of laminated material, called the lower interlayer (32; 32'), thermoplastic, with a thickness Ei preferably of at least 20 pm the laminate has a light extraction layer which includes 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 a thickness Ep preferably of 50pm to 100pm.

12. Functional laminate according to claim 11 characterized in that it has a peel resistance 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 100pm, preferably with a peel strength between the fluoropolymer film and the lower interlayer of at least 2N / mm and even of at least 3 N / m.

14. Functional laminate according to any one of claims 10 to 13 characterized in that the lower interlayer is PVB-based 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 functional laminate according to any one of claims 10 to 14, in wound strip, preferably of a width of at least 600mm and / or of a length of at most 300mm and optionally comprising a temporary protective film.

16. A method for forming a roll of said laminate according to the preceding claim, comprising: - a first continuous drawing of the optical insulating layer in strip form with said first thermoplastic film, which is a first fluoropolymer film or a first thermoplastic film bearing an optical insulating coating, - a second continuous drawing of the first interlayer in strip form, and in sheet form, having a smooth principal rear face with a roughness defined by an Rz parameter of at most 50 µm, preferably a second drawing separate from the first drawing, - a third continuous drawing 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 µm, in particular a third drawing separate from or combined with the second drawing, - heating of the first interlayer in strip form - heating of the lower interlayer layer in strip form when the third print is separated from the second print, the light extraction layer being on the lower interlayer layer or on the optical insulator layer, in the form of a diffusing coating in one or more diffusing patterns preferably with a coverage rate of no more than 30% - the formation of the laminate by calendering in this order of the first heated interlayer layer, the first film, the lower interlayer layer possibly heated - the winding of the laminate onto the so-called winder roller.

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

18. A 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, referred to as the first interlayer unwinding roll, comprising the first interlayer layer (31) in strip form, preferably made of PVB with at least 20% plasticizer; - the unwinding of a composite roll, comprising a laminated bilayer comprising the optical insulating layer with said first film, thermoplastic, and the lower interlayer layer, which is made of PVB with at most 5% or 1% plasticizer, of thickness Ei of at most 80 µm, having a principal bonding face with the first

19.

20. 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. A method for forming a roll of said laminate according to any 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 the insulating composition to form the optical insulating coating, preferably during said initial printing, - the liquid deposition onto 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, particularly during the initial printing or as a rework during a subsequent printing - a possible winding of the first film with the optical insulating coating and the light extraction layer in a winding roller, a roll that can be unwound for the second print. A method for forming a roll of said laminate according to any one of claims 16 to 18, characterized in that it comprises: -the unwinding of a primary unwinding roller 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, particularly in strip and sheet form, - or the unwinding of a primary roll of interleaving material comprising the lower interleaving layer in strip and sheet form, the lower interleaving layer being PVB-based with at most 5% plasticizer, of thickness Ei of at most 80 µm, and followed - the liquid deposition on the optical insulating coating or on the lower interlayer (back or front face) of a composition called the extracting composition comprising a matrix in particular crosslinkable and diffusing particles, layer in one or more motifs, to form the light extraction layer.