Substrate with a flammable coating mask

Abstract

To provide a substrate with a functional coating over certain sections of the substrate and no functional coating over other sections of the substrate without the use of laser deletion.SOLUTION: A substrate 100 with a burnable coating mask comprises: a substrate 102 having a first section 104 and a second section 106; a mask coating layer 108 over the first section 104 of the substrate 102; and a functional coating layer 110 over at least a portion of the mask coating layer 108 and over the second section 106 of the substrate 102. A method of segmenting a substrate having a layer thereover, a method of preparing a segmented substrate having a layer thereover, a segmented substrate, and a transparency are also disclosed.SELECTED DRAWING: Figure 1A

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority to U.S. Patent Application No. 16 / 913,305, filed June 26, 2020, which claims priority to U.S. Provisional Patent Application No. 62 / 868,324, filed June 28, 2019, and U.S. Provisional Patent Application No. 63 / 018,596, filed May 1, 2020, all of which are incorporated by reference in their entireties.

[0002] (Technical field) The present invention relates to a substrate having a flammable coating mask, a method for segmenting a substrate having a layer thereon, a method for preparing a segmented substrate having a layer thereon, a segmented substrate, and a transparency. [Background technology]

[0003] In certain applications, it may be desirable to have a substrate that has a functional coating on certain sections of the substrate and not on other sections of the substrate. As an example, some automobile manufacturers utilize infrared cameras or rain detectors whose sensors are obstructed by the presence of a functional coating on certain sections of the substrate through which the sensors transmit infrared (or other) radiation.

[0004] One procedure for producing such substrates is to use laser deletion to remove the functional coating from the relevant sections of the substrate. However, some customers reject substrates produced using laser deletion because the laser deletion technique incompletely removes the functional coating in certain cases.

[0005] Therefore, it is desirable to create a substrate that has a functional coating on certain sections of the substrate and does not have the functional coating on other sections of the substrate without the use of laser ablation. Summary of the Invention

[0006] The present invention relates to a substrate having a flammable coating mask, including a substrate having a first surface and a second surface opposite the first surface. The first surface has a first section and a second section adjacent to the first section. A mask coating layer is disposed on the first section of the first surface. The mask coating layer is not disposed on the second section of the first surface. A functional coating layer is disposed on at least a portion of the mask coating layer and on the second section of the substrate. When the coated substrate is heated, the flammable coating mask and a portion of the functional coating layer on the flammable coating mask are removed, leaving an area on the substrate without the functional coating layer.

[0007] The present invention also relates to a method for segmenting a substrate. A substrate having a flammable coating mask is provided. The substrate includes a first surface and a second surface opposite the first surface. The first surface has a first section and a second section adjacent to the first section. A mask coating layer is disposed on the first section. The mask coating layer is not disposed on the second section of the first surface. A functional coating layer is disposed on at least a portion of the mask coating layer and on the second section of the substrate. The coated substrate is heated such that the mask coating layer is removed from the first section. A portion of the functional coating disposed on the mask coating layer is also removed from the first section. The portion of the functional coating disposed on the second section remains substantially incorporated on the substrate.

[0008] The present invention also relates to a method for preparing a segmented substrate. A substrate is provided having a first surface and a second surface opposite the first surface. The first surface has a first section and a second section adjacent to the first section. A material is applied onto the first section of the first surface to form a mask coating layer. The mask coating layer is not disposed on the second section of the first surface. A functional coating layer is applied over at least a portion of the mask coating layer and onto the second section of the first surface to form the functional coating layer.

[0009] The present invention also relates to a method of preparing an automotive transparency, the method comprising the steps of: providing a first ply having a No. 1 surface and a No. 2 surface opposite the No. 1 surface; providing a second ply having a No. 3 surface and a No. 4 surface opposite the No. 3 surface, wherein the No. 1 surface, the No. 2 surface, the No. 3 surface, or the No. 4 surface has a first section and a second section adjacent the first section; a mask coating layer is on the first section and not on the second section; and a functional coating layer is on at least a portion of the mask coating layer and on the second section; simultaneously or separately heating the first ply and the second ply; and removing the mask coating layer and a portion of the functional coating disposed on the mask coating layer to form the automotive transparency. [Brief explanation of the drawings]

[0010] [Figure 1A] FIG. 1A illustrates a cross-sectional view of a substrate having a flammable coating mask, according to some non-limiting embodiments. [Figure 1B] FIG. 1B shows a cross-sectional view of a segmented substrate prepared using a flammable coating mask, according to some non-limiting embodiments.

[0011] [Figure 2A]FIG. 2A illustrates a cross-sectional view of a substrate having a flammable coating mask, according to some non-limiting embodiments. [Figure 2B] FIG. 2B shows a cross-sectional view of a segmented substrate prepared using a flammable coating mask, according to some non-limiting embodiments. [Figure 3A] FIG. 3A illustrates a cross-sectional view of a substrate having a flammable coating mask, according to some non-limiting embodiments. [Figure 3B] FIG. 3B shows a cross-sectional view of a segmented substrate prepared using a flammable coating mask, according to some non-limiting embodiments.

[0012] [Figure 4] FIG. 4 shows a top view of a segmented substrate, according to some non-limiting embodiments.

[0013] [Figure 5A] FIG. 5A shows a cross-sectional view of a transparency, according to some non-limiting embodiments. [Figure 5B] FIG. 5B illustrates a cross-sectional view of a transparency, according to some non-limiting embodiments.

[0014] [Figure 6] FIG. 6 shows a photomicrograph of the coated substrate including the mask coating layer after heating. DETAILED DESCRIPTION OF THE INVENTION

[0015] For purposes of the following description, the terms "end," "upper," "lower," "right," "left," "vertical," "horizontal," "top," "bottom," "transverse," "longitudinal," and their derivatives shall refer to the present invention as illustrated in the drawings. However, it should be understood that the present invention may contemplate various alternative modifications and step sequences, unless expressly specified to the contrary. It should also be understood that the specific devices and processes illustrated in the accompanying drawings and described in the following specification are merely exemplary embodiments or aspects of the present invention. Therefore, specific dimensions and other physical characteristics related to the embodiments or aspects disclosed herein are not to be considered limiting.

[0016] For purposes of the following detailed description, it should be understood that the present invention, unless expressly stated to the contrary, can encompass various alternative modifications and step sequences. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0017] It should be understood that any numerical range recited herein is intended to include all subranges subsumed therein. For example, a range of "1 to 10" is intended to include all subranges between (and including) the stated minimum of 1 and the stated maximum of 10, i.e., from a minimum of 1 or more to a maximum of 10 or less.

[0018] With respect to layers of material described herein, the term "over" means further from the substrate on which the material is disposed. For example, a second layer disposed "over" a first layer means that the second layer is disposed further from the substrate than the first layer. The second layer may be in direct contact with the first layer. Alternatively, one or more other layers may be disposed between the first and second layers.

[0019] The terms "polymer" or "polymeric" include oligomers, homopolymers, copolymers, and terpolymers, eg, polymers formed from two or more types of monomers or polymers.

[0020] As used herein, the transitional term "comprising" (and other equivalent terms, e.g., "containing" and "including") is "open-ended" and can include unspecified items. Although described with the term "comprising," the terms "consisting essentially of" and "consisting of" are also within the scope of this disclosure.

[0021] 1A-5 having the same last two digits in their element numbers correspond to elements in other figures of the present application and will be understood to include the same characteristics of the corresponding elements, except where expressly stated. For example, elements 102, 202, 302, etc. all refer to the substrate described below, as all of these element numbers have the same last two digits (02).

[0022] Referring to FIG. 1A, a substrate 100 having a flammable coating mask is shown, according to some non-limiting embodiments. The substrate 100 having a flammable coating mask can include a substrate 102 having a first section 104 and a second section 106 on its surface. The substrate 102 can be made of any suitable material. The substrate 102 can be transparent or translucent to visible light. "Transparent" means having a visible light transmittance of greater than 0% to 100%. "Translucent" means allowing electromagnetic energy (e.g., visible light) to pass through but diffusing this energy so that objects on the opposite side of the viewer cannot be clearly seen. Examples of such materials include, but are not limited to, plastic substrates (such as acrylic polymers such as polyacrylates; polyalkyl methacrylates such as polymethyl methacrylate, polyethyl methacrylate, polypropylene methacrylate; polyurethanes; polycarbonates; polyalkyl terephthalates such as polyethylene terephthalate (PET), polypropylene terephthalate, polybutylene terephthalate; polysiloxane-containing polymers; or copolymers of any monomers therefor, or any mixtures thereof), ceramic substrates, glass substrates, or mixtures or combinations of any of the above. For example, the substrate 102 can comprise conventional soda-lime silicate glass, borosilicate glass, or leaded glass. The glass can be uncoated glass. The glass can be clear glass. "Clear glass" means non-tinted glass or uncolored glass. Alternatively, the glass can be tinted or otherwise colored glass. The glass may be of any type, such as conventional float glass, and may be of any composition having any optical properties, for example, any values ​​of visible transmittance, ultraviolet transmittance, infrared transmittance, and / or total solar energy transmittance."Float glass" means glass formed by the conventional float process in which molten glass is deposited onto a bath of molten metal and controllably cooled to form a float glass ribbon. Examples of float glass processes are disclosed in U.S. Patent Nos. 4,466,562 and 4,671,155.

[0023] The substrates 102 may each be, for example, clear float glass or tinted or colored glass. Non-limiting examples of glass suitable for the substrates 102 are described in U.S. Patent Nos. 4,746,347; 4,792,536; 5,030,593; 5,030,594; 5,240,886; 5,385,872; and 5,393,593. The substrates 102 may be of any desired dimensions, such as length, width, shape, or thickness. In one exemplary substrate used in an automotive transparency, the substrate 102 may be 1 mm to 10 mm thick, such as 1 mm to 8 mm thick, such as 2 mm to 8 mm thick, such as 3 mm to 7 mm thick, such as 5 mm to 7 mm thick, or 6 mm thick. Non-limiting examples of glasses that can be used in the practice of the present disclosure include clear glasses commercially available from PPG Industries Inc. of Pittsburgh, Pennsylvania: Starfire®, Solargreen®, Solextra®, GL-20®, GL-35™, Solarbronze®, Solargray® glass, Pacifica® glass, SolarBlue® glass, and Optiblue® glass.

[0024] 1A , the substrate 100 having the flammable coating mask may include a material applied onto a first section 104 of the substrate 102 to form a mask coating layer 108, but not onto a second section 106 of the substrate. The mask coating layer 108 may be selectively disposed on certain sections of the substrate 102 (e.g., the first section 104) while avoiding being disposed on other sections of the substrate 102 (e.g., the second section 106). The mask coating layer 108 may be formed directly on (in direct contact with) the substrate 102, or the mask coating layer 108 may be formed indirectly on the substrate 102 (with at least one intervening coating layer between the substrate 102 and the mask coating layer 108). Preferably, the mask coating layer 108 is formed directly on the substrate 100. The mask coating layer 108 may be applied using any suitable application method, including, but not limited to, inkjet printing, silkscreen printing, stamping, etc. The method may further include preparing the material via an emulsion in which the material is dispersed in water or an aqueous medium. As used herein, an "aqueous medium" is a liquid mixture containing more than 50% water. It is understood that more than 50% water is relative to the total liquid content, so that any solids present are not taken into account. The mask coating layer 108 may have a thickness in the range of 10 nm to 2000 μm, for example, 10 nm to 1000 μm, 10 nm to 500 μm, 0.5 μm to 100 μm, 0.5 μm to 10 μm, 10 μm to 30 μm, or 50 μm to 100 μm.

[0025] The mask coating layer 108 may include a material including a wax, an organic oil (e.g., tung oil), a polyolefin, a (meth)acrylate (e.g., poly(meth)acrylate) (as understood herein, (meth)acrylate refers to both acrylate and methacrylate), a polyester, an alkene, a polyethylene, a polypropylene, an emulsion thereof, or some combination thereof. The mask coating layer 108 may include polylactic acid (PLA), polyethylene carbonate (PEC), polypropylene carbonate (PPC), polycaprolactone, polyoxymethylene, polyethylene, polypropylene, or some combination thereof. The wax may include stearic acid, paraffin, carnauba, microcrystalline wax, polyethylene wax, or some combination thereof. Examples of wax emulsions include those available from Michelman, Inc. (Cincinnati, Ohio) (e.g., MGRD 1350, ML160, ME62330, Aqua240 PH90602L, ME48040M2) or those available from BYK-Chemie GmbH (Wesel, Germany) (e.g., AQUACER 526, AQUACER 541, AQUACER 1031, AQUACER 8500). The wax emulsion may be a paraffin / polyethylene emulsion, anionic polyamide emulsion, anionic carnauba emulsion, amine-dispersed carnauba emulsion, ethylene acrylic acid emulsion, nonionic microcrystalline emulsion, or some combination thereof. In some non-limiting examples, the mask coating layer 108 may include an alkane, an ester, or a carboxylic acid and may have at least 40% by weight (e.g., at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% by weight) of carbon, based on the total weight of the mask coating layer 108. The material may be mixed with a solvent. For example, the material may include a mixture of PLA and methyl acetate.

[0026] Alternatively, the mask coating layer 108 may include, in addition to any of the aforementioned materials, a polyurethane material, an epoxide material, a polyurea material, or a combination thereof. As used herein, a "polyurethane material" refers to a material that forms at least a portion of the mask coating layer 108, contains urethane linkages, and / or is made from components that include polyurethane. Examples of polyurethanes that can be used include water-based polyurethanes, polyurethanes formed from two-component systems, emulsions thereof, and combinations thereof. Polyurethanes may contain additional functional groups, including ester linkages, ether linkages, and hydrophilic groups such as hydroxyl groups, carboxyl groups, carbonyl groups, amino groups, and thiols. Hydrophilic functional groups may be incorporated into polyurethanes to aid in emulsion formation. Polyurethanes can be obtained by reacting one or more hydroxyl-functional compounds with one or more isocyanate-functional compounds. The hydroxyl-functional compounds can include diols and / or polyols having three or more hydroxyl functional groups. The isocyanate-functional compounds can include compounds having two or more isocyanate functional groups, for example, compounds having three or more isocyanate functional groups. The isocyanate-functional compound can include an unblocked isocyanate, a blocked isocyanate, a partially blocked isocyanate, or a combination thereof.

[0027] As shown, the mask coating layer 108 may include an epoxide material. As used herein, an "epoxide material" is a material that includes an epoxide or is derived from a component that includes an epoxide. Examples of epoxides include epoxy-functional polymeric materials, also known as polyepoxides, that include two or more epoxy functional groups. The epoxide may be an emulsion. The epoxide may include one or more additional functional groups (e.g., carboxylic acid and / or hydroxyl functional groups) and may react with itself as a self-crosslinking compound to form a reaction product. Alternatively, the epoxide may be reacted with a second compound, such as a carboxylic acid and / or hydroxyl functional compound, to form a reaction product. If excess epoxy functional groups are present in the reactants, the epoxide may include epoxy functional groups. Alternatively, all of the epoxy functional groups may react to form the epoxide layer during the reaction, such that no epoxy functional groups are present in the mask coating layer 108.

[0028] As shown, the mask coating layer 108 may include a polyurea material. As used herein, a "polyurea material" is a material that includes urea linkages and / or is formed from components that include polyurea.

[0029] The mask coating layer 108 may include both a polyurethane material and an epoxide material. When both a polyurethane material and an epoxide material are present, the polyurethane material and the epoxide material may be formed together such that the mask coating layer 108 includes one layer containing both a polyurethane and an epoxide. Alternatively, when both a polyurethane material and an epoxide material are present, the polyurethane material and the epoxide material may be formed as separate layers. For example, the polyurethane material may be formed on the substrate, and the epoxide material may be formed on the polyurethane material, as separate layers. As a further example, the epoxide material may be formed on the substrate, and the polyurethane material may be formed on the epoxide material, as separate layers.

[0030] As used herein, the term "1-component" or "1K" refers to a coating composition in which all coating components are combined and stored in a single container. As used herein, the term "2-component" or "2K" refers to a coating composition in which the components are stored separately and react and crosslink when mixed together to form a crosslinked material.

[0031] The materials applied to form the mask coating layer 108 may be thermoplastic or thermosetting. As used herein, a "thermoplastic" refers to a material that softens when heated and has a defined melting point. The materials applied to form the mask coating layer 108 may be thermosetting versions of any of the aforementioned materials for the mask coating layer 108. As used herein, a "thermosetting" refers to any cross-linked material that does not have a defined melting point, but instead burns or decomposes when heated. The materials applied to form the mask coating layer 108 may have a low degree of cross-linking, such that the material has a defined melting point. The materials applied to form the mask coating layer 108 may have a high degree of cross-linking, such that the material does not have a defined melting point. A high degree of cross-linking can be achieved, for example, via a solvent-based formulation or by adding a cross-linking agent to an aqueous formulation.

[0032] The mask coating layer 108 can include a material that, when included in a composition, applied to a substrate, and solidified, forms a layer that exhibits a water contact angle (WCA) (when contacted with water) of at least 60° (e.g., at least 70° or at least 80°). The mask coating layer 108 may also include a hydrophobic material. A hydrophobic material is defined herein as a material that, when included in a composition, applied to a substrate, and solidified, forms a layer that exhibits a WCA (when contacted with water) of at least 90° (e.g., at least 100°, at least 110°, at least 120°, at least 130°, at least 140°, or at least 150°).

[0033] The mask coating layer 108 may comprise a material having a melting point of at least 60°C, e.g., at least 70°C or at least 80°C. The mask coating layer 108 may have a melting point between 60°C and 350°C. The mask coating layer 108 may comprise a material that, when solidified, is impermeable to water and other standard processing fluids, such as coolants, cutting oils, etc. A mask coating layer 108 disposed over a substrate may provide improved corrosion protection compared to an identical substrate without the mask coating layer 108 disposed thereon.

[0034] In some non-limiting examples, the material applied to form the mask coating layer 108 may include an emulsion including a hydrophobic material, water, and a surfactant, where the surfactant may be a non-ionic surfactant or an ionic surfactant (e.g., a cationic or anionic surfactant). The material applied to form the mask coating layer 108 may include a material including a hydrophobic material dissolved in a solvent. The material applied to form the mask coating layer may include a UV-curable or heat-curable material that, when applied to the surface of the substrate and exposed to a UV or heat source, results in crosslinking of the material applied to the substrate. The material applied to form the mask coating layer may include a two-component (2K) resin containing separate components that, when mixed together, react to crosslink the material when applied to the surface of the substrate.

[0035] In some non-limiting examples, the material is heated to a temperature at least equal to the glass transition temperature ("Tg") of the material, and the material is applied at a temperature at least equal to the Tg of the material. In other non-limiting examples, the material is applied below the Tg of the material and then heated to a temperature suitable for softening the material (e.g., a temperature above the Tg of the material). Non-limiting examples include carnauba wax, such as ML160 available from Michelman, Inc. (Cincinnati, Ohio), which may require heat treatment to a temperature with a Tg greater than 63°C (e.g., at least 70°C, at least 80°C, or at least 90°C). The material may also require a curing step at a temperature for a period of time. For example, the material may be cured at room temperature (i.e., in the range of 20-27°C, e.g., 25°C) for a period of up to 72 hours, or up to 48 hours, or up to 36 hours, or up to 24 hours. The material may also be cured at elevated temperatures, such as in the range of 90-180°C, or 100-170°C, or 110-150°C, or 120-130°C (e.g. 121°C), for up to 2 hours, such as 1 hour, for example 30 minutes, for example 15 minutes.

[0036] The mask coating layer 108 may contain any additional components. Non-limiting examples of additional components include plasticizers, crosslinkers, viscosity modifiers, corrosion inhibitors, infrared (IR) absorbers, adhesion modifiers, UV absorbers, pigments, surfactants, and hydrophobic agents. Examples of plasticizers suitable for use in the mask coating layer 108 composition include oils such as cottonseed oil, epoxidized soybean oil, and canola oil; waxes such as carnauba wax, paraffin, and microcrystalline wax; polyethylene glycol; and polypropylene glycol. The plasticizer is included in the mask coating layer 108 composition to aid in removal of the mask coating layer 108 via an abrasion wheel, particularly when the mask coating layer 108 is a thermosetting resin-based material. The plasticizer may be included in the mask coating layer 108 in an amount ranging from 1 to 50% by weight, or from 4 to 40% by weight, or from 10 to 30% by weight, based on the total solids content of the mask coating layer 108.

[0037] Examples of suitable viscosity modifiers include RHEOBYK-425, RHEOBYK-T 1000VF, RHEOBYK-L 1400 VF, and RHEOBYK-H 3300 VF, available from BYK, and H1335 and HY124, available from Spectrum. The viscosity modifier may be included in the mask coating layer 108 in an amount ranging from 0.05 to 20 wt %, or 0.1 to 15 wt %, or 0.1 to 10 wt %, based on the total components of the coating mask layer 108.

[0038] Examples of suitable hydrophobic agents include waxes, oils, and fatty acids. The hydrophobic agent may be included in the mask coating layer 108 in an amount ranging from 0.5 to 70 wt %, or from 1 to 65 wt %, or from 1 to 60 wt %, based on the total solids content of the mask coating layer 108.

[0039] Examples of crosslinking agents suitable for use in the composition of the mask coating layer 108 include compounds containing an aziridine group. A non-limiting example of a compound containing an aziridine group that can be used in the mask coating layer 108 is trimethylolpropane tris(2-methyl-1-aziridinepropionate). The crosslinking agent may be included in the mask coating layer 108 in an amount ranging from 0.05 to 30 wt %, or from 0.1 to 20 wt %, or from 0.1 to 10 wt %, based on the total solids content of the mask coating layer 108. The crosslinking agent is included in the composition of the mask coating layer 108 to crosslink the composition (e.g., to create a thermoset resin system).

[0040] The mask coating layer 108 may include inorganic compounds such as talc, silica, metal catalysts, inorganic pigments, etc. Alternatively, one or more coating layers (e.g., one or all coating layers) may not include any of the aforementioned additional components, such as not including inorganic compounds such as talc, silica, metal catalysts, inorganic pigments, etc.

[0041] Additional additives, such as cross-linking agents, may be added during the preparation of the material that forms the mask coating layer 108. Alternatively, the additional additives may be added immediately before the material is applied to form the mask coating layer 108.

[0042] 1A , the substrate 100 having the flammable coating mask may include a functional coating material applied over at least a portion of the mask coating layer 108 and over the second section 106 of the substrate 102 to form a coating layer 110. The coating layer 110 may have a functional coating layer. The coating layer 110 may have a protective layer over the functional coating layer. The functional coating layer may have a thickness of less than 1 μm.

[0043] As used herein, the term "functional coating layer" refers to a coating that provides a functional benefit to a surface beyond surface decoration. Non-limiting examples include coatings that impart optical, structural, electrical, hygienic, thermal, and / or physicochemical properties to a surface. Non-limiting examples of functional coatings include at least one of a low-e (low emissivity) coating, a hydrophilic coating, a hydrophobic coating, an oleophilic coating, a low-friction coating, an antibacterial coating, an anti-fingerprint coating, an anti-fog coating, a self-cleaning coating, an easy-to-clean coating, a transparent conductive coating, and combinations thereof. The functional coating layer may include a solar control coating. As used herein, the term "solar control coating" refers to a coating composed of one or more layers or films that affect the solar properties of the coated article, such as, but not limited to, the amount of solar radiation, such as visible, infrared, or ultraviolet radiation, that is reflected from, absorbed by, or transmitted through the coated article, the shading coefficient, the emissivity, etc.; solar control coatings can block, absorb, or filter selected portions of the solar spectrum, such as, but not limited to, the IR, UV, and / or visible spectrum.

[0044] The functional coating layer can be a single layer coating or a multi-layer coating. The functional coating layer can be a multi-layer solar control coating such as described in U.S. Patent Application Publication No. 2017 / 0341977.

[0045] The functional coating layer can include any temperable coating layer, such as those disclosed in GB Patent No. 2,302,102, U.S. Patent No. 4,504,109; U.S. Patent No. 4,952,423; U.S. Patent No. 5,028,759; U.S. Patent No. 5,059,295; U.S. Patent No. 5,653,903; U.S. Patent No. 7,749,621; U.S. Patent No. 8,865,325; and U.S. Patent Application Publication No. 2014 / 0272453. The functional coating layer may include coatings available under the Solarban® or Sungate® tradenames, commercially available from Vitro Architectural Glass (Cheswick, PA).

[0046] The functional coating layer may include a metal layer comprising a metallic material such as gold, copper, aluminum, palladium, or a combination thereof. The functional coating layer can be applied to the substrate using magnetron sputtering deposition ("MSVD") (e.g., MSVD-coated glass, etc.). Non-limiting examples of suitable functional coatings and coated substrates are disclosed in U.S. Patent Application Publication Nos. 2017 / 0341977, 2018 / 0118614, 2019 / 0204480, U.S. Patent Nos. 7,335,421, 8,865,325, 9,932,267, and 10,479,724, all of which are incorporated herein by reference in their entireties.

[0047] A protective layer may be applied over the functional coating layer. The protective layer can help protect the underlying coating layer (e.g., the functional coating layer and its constituent films and layers) from mechanical and / or chemical attack. The protective layer may be composed of Si3N4, SiAlN, SiAlON, titania, alumina, silica, zirconia, tin oxide, mixtures thereof, and / or alloys thereof, and can provide enhanced durability to the functional coating layer. For example, the protective layer may be SiAlN, Si3N4, TiAlO, or TiO2. The protective layer can have a thickness in the range of 10 Å to 800 Å, e.g., 100 Å to 800 Å, e.g., 100 Å to 400 Å, e.g., 350 Å to 400 Å, or in the range of 100 Å to 400 Å, e.g., 200 Å to 300 Å, e.g., 270 Å to 330 Å, e.g., 10 Å to 80 Å, e.g., 45 Å to 55 Å. The protective layer may be the top layer of the substrate.

[0048] Referring to FIG. 2A , a substrate 200 having a flammable coating mask is shown according to some non-limiting embodiments. The substrate 200 having a flammable coating mask may have the same properties as the substrate 100 having a flammable coating mask described in FIG. 1A , with the following exceptions: The substrate 200 having a flammable coating mask may further include a temporary protective material applied over at least a portion of the coating layer 210 to form a temporary protective layer 212. The temporary protective layer 212 may be disposed over the entire substrate 202 or may be selectively disposed over specific sections of the substrate 202. The temporary protective layer 212 may be the outermost layer on the substrate 202.

[0049] The materials used to form the temporary protective layer 212 may include any of the materials previously described to be used to form the mask coating layer 208. The temporary protective layer 212 may be formed from the same or different materials as the mask coating layer 208.

[0050] Referring to FIG. 3A , a substrate 300 having a flammable coating mask is shown according to some non-limiting embodiments. The substrate 300 having a flammable coating mask may have the same characteristics as the substrate 100 having a flammable coating mask described in FIG. 1A , with the following exceptions: As shown in FIG. 1A , the coating layer 110 may have a non-uniform thickness, such that the coating layer 110 has a first thickness on the second section 106 and a second thickness on the first section 104. The first thickness may be greater than the second thickness. The first and second thicknesses may be such that the surface of the coating layer 110 is substantially the same distance from the substrate 102 throughout the entire coating layer 110. The substrate 300 with a flammable coating mask of FIG. 3A differs from the substrate 100 with a flammable coating mask of FIG. 1A in that the substrate 300 with a flammable coating mask of FIG. 3A has a coating layer 310 with a substantially uniform thickness (e.g., within 5% of the average thickness throughout the coating layer 310). In this manner, the surface of the coating layer 310 may be at a different distance from the substrate 302 in a particular section of the coating layer 310. For example, as shown in FIG. 3A, the surface of the coating layer 310 on the first section 304 may be farther from the substrate 302 than the surface of the coating layer 310 on the second section 306 by the thickness of the mask coating layer 308.

[0051] Referring to FIGS. 1B, 2B, and 3B, segmented substrates 101, 201, and 308 prepared using a flammable coating mask are shown. The segmented substrates 101, 201, and 308 in FIGS. 1B, 2B, and 3B correspond to the substrates 100, 200, and 300 with the flammable coating masks in FIGS. 1A, 2A, and 3A, respectively, after undergoing a heat treatment process to form the segmented substrates 101, 201, and 308. The heat treatment process can remove the mask coating layer and / or the temporary protective layer. A portion of the coating layer disposed above the mask coating layer may be removed during the heat treatment process as a result of the underlying mask coating layer being removed during the heat treatment process. When the mask coating layer is removed by the heat treatment process, a first section of the substrate may be exposed.

[0052] Materials used to form the mask coating layer and / or temporary protective layer may be "burnable" so as to be removable by a thermal treatment process. As used in this disclosure, the term "burnable" refers to materials (as defined below) that burn, vaporize, or pyrolyze from the substrate, interact with the substrate, or substantially damage the aesthetics or performance of the substrate (including any coatings thereon). Flammable materials may burn, vaporize, or pyrolyze when the substrate temperature is at least 500°C to 1000°C. It is expected that the flammable materials will burn, vaporize, or otherwise pyrolyze before the substrate reaches a temperature of 1000°C from the thermal treatment process (e.g., at temperatures of 900°C, 800°C, 700°C, or 650°C). The thermal treatment process can be carried out in a furnace having a temperature of up to 1200°C (e.g., up to 1100°C, 1000°C, 900°C, 800°C, 700°C, or 650°C). The furnace can operate at a temperature of 700°C so that the substrate reaches a temperature of 640°C to burn off the mask coating layer and / or temporary protective layer that is removed during the heat treatment process. In some non-limiting embodiments, the combustible material may be removed during a standard heat treatment process, such as tempering, heat strengthening, or bending, as described above, or during a heat treatment specifically performed to remove the combustible material without adversely affecting the substrate. In some non-limiting examples, the combustible material may be removed during a standard tempering procedure, where the tempering oven operates in the range of 500°C to 1000°C.

[0053] The mask coating layer and / or temporary protective layer may be configured to be removable by a heat treatment process without substantially damaging the first section of the substrate. As used herein, "substantially damaging" is defined as any undesirable change in substrate properties that adversely affects the function or aesthetics of the first section of the substrate and renders the substrate unacceptable for its intended purpose. For example, substantially damaging the surface may include substantial discoloration to the surface from the heat treatment process. In other applications where a heating step is part of the standard procedure, damage may be defined as an undesirable color change due to the presence of the mask coating layer and / or temporary protective layer. As used herein, substantial discoloration means a color change (DECMC) of more than 3 units, more than 2 units, or more than 1 unit compared to the color of a similar substrate processed without the mask coating layer and / or temporary protective layer. DECMC (CIELAB) can be measured using an integrating sphere with D65 illumination and a 10° observer including a specular component according to ASTM Designation: D2244-05, unless otherwise specified. Other examples of substantial damage include those caused by or resulting from changes in surface roughness, surface oxidation state, or surface energy, which may be due to the presence of a mask coating layer and / or temporary protective layer during the heat treatment process, or an undesirable reaction between the mask coating layer and / or temporary protective layer and the substrate during the heat treatment process. Substantial damage may include deleterious changes to the functional coating layer (e.g., an antimicrobial functional coating that no longer disinfects the surface after the heat treatment process, a hydrophobic functional coating that loses its hydrophobicity after the heat treatment process, or a color change in the functional coating that is discernible to the human eye (e.g., DECMC>3, 2, or 1) compared to a substrate heated without the mask coating layer and / or temporary protective layer).

[0054] Referring to FIG. 4 , a plan view of a segmented substrate 401 is shown, according to some non-limiting embodiments. The segmented substrate 401 can include an exposed first section 404 of the substrate with a coating layer 410, which is disposed on a second section of the substrate 401 but not on the first section 404 of the substrate. The coating layer 410 can be exposed as the outermost layer of the segmented substrate 401. The segmented substrate can be prepared by providing any of the aforementioned substrates with a flammable coating mask and applying a heat treatment to the substrate with the flammable coating mask such that the mask coating layer is removed from the first section 404, thereby removing any coating layers applied over the mask coating layer. The heat treatment can also remove any of the aforementioned temporary protective layers.

[0055] A method for segmenting a substrate having at least one layer thereon can include providing any of the aforementioned substrates with a flammable coating mask and heating the substrate with the flammable coating mask so that the mask coating layer and a portion of the functional coating on the mask coating layer are removed from a first section. The heating step can also remove any of the aforementioned temporary protective layers. The heating step can include any of the aforementioned heat treatment processes.

[0056] A method for preparing a segmented substrate having at least one layer thereon may include providing a substrate having a first surface and a second surface opposite the first surface. The first surface has a first section and a second section adjacent to the first section. A first material may be applied onto the first section to form a mask coating layer. The mask coating layer is not applied onto the second section. A functional material may be applied onto at least a portion of the mask coating layer and onto the second section of the first surface to form a functional coating layer of the coating layer. The substrate including the mask coating layer may be cleaned and / or shipped to a desired destination before applying the functional coating. A second material may be applied onto at least a portion of the coating layer to form a temporary protective layer. The first and second materials may be the same or different materials.

[0057] 5A-5B, a transparency 514 (e.g., an automotive transparency) is shown according to some non-limiting embodiments. The transparency 514 may include a first ply 516 having a first major surface 518 (the No. 1 surface) and an opposing second major surface 520 (the No. 2 surface). In the illustrated non-limiting embodiment, the first major surface 518 faces outward (e.g., toward the sun), i.e., is the exterior major surface, and the second major surface 520 faces inward. The transparency 514 may also include a second ply 522 having an exterior (near-exterior) first major surface 524 (the No. 3 surface) and an interior (second) major surface (the No. 4 surface). This ply surface numbering is consistent with conventional practice in the automotive industry. The first ply 516 and the second ply 522 can be bonded together in any suitable manner and may include a conventional interlayer 530 between the first ply 516 and the second ply 522. As shown in FIGS. 5A-5B, the first ply 516 or the second ply 522 may be a segmented substrate 501 prepared from a substrate having a flammable coating mask. The coating layer 510 may be formed on at least a portion of one of the plies 516, 522 (e.g., its second section 506), such as, but not limited to, on at least a portion of the No. 3 surface 526 (FIG. 5A) or on at least a portion of the No. 2 surface 520 (FIG. 5B). The functional coating 510 may also be on the No. 1 surface or the No. 4 surface, as needed. After the heating and bending steps described herein, the flammable coating mask is burned off the plies 516, 522, leaving a first section of the plies 516, 522 devoid of the coating and a second section retaining the coating 510.

[0058] The transparency 514 can be prepared by providing a substrate having a flammable coating mask (as the first ply 516 and / or the second ply 522) and applying a heat treatment to the substrate such that the mask coating layer is removed from the first section 504. The substrate having the flammable coating mask may include a temporary protective layer that can be removed by the heat treatment.

[0059] Transparency 514 may be a transparency in any desired field, including, but not limited to, transparencies for land, air, space, surface, and underwater vehicles. Furthermore, while a typical "transparency" may have sufficient visible light transmittance such that the material can be seen through the transparency, in the practice of the present invention, a "transparency" need not be transparent to visible light, but may be translucent or opaque.

[0060] In some non-limiting examples, the transparent body 514 may be a vehicle windshield. The vehicle may utilize autonomous vehicle technology such as detectors and / or sensors (hereinafter collectively referred to as "sensors") (e.g., infrared cameras, LIDAR, rain detectors, etc.). The sensors may be located inside the vehicle, and radiation or other sensing mechanisms emitted by the sensors may travel through the transparent body 514 to the outside of the vehicle to sense the surroundings. The functional coating layer of the coating layer 510 of the transparent body 514 may interfere with radiation emitted by the sensors, so that the sensors may be positioned such that radiation emitted therefrom passes through the first section 504 of the segmented substrate 501. The first section 504 of the segmented substrate 501 may be uncoated or may have a coating thereon that does not affect the sensing capabilities of the sensors. Thus, the first section 504 may be selectively positioned on the segmented substrate 501 based on the location of the sensors within the vehicle. This means that the segmented substrate 501 can be prepared from a substrate having a flammable coating mask on the first section 504 such that the segmented substrate 501 is compatible with the location of the sensor in the vehicle (does not adversely affect the sensor) after a heat treatment process to remove the flammable coating mask.

[0061] In some non-limiting embodiments, a method for preparing an automotive transparency may include providing a first ply having an outer first major surface and an opposing inner second major surface, as described above, and providing a second ply having a flammable coating mask. Alternatively, the first ply may have a flammable coating mask as described above. The second ply has an inner third major surface and an opposing outer fourth major surface, the third major surface having a first section and a second section adjacent to the first section. A mask coating layer may be on the first section. A functional coating layer may be on at least a portion of the mask coating layer and on the second section.

[0062] The method may include heating the first ply and the second ply to a temperature sufficient to bend the first ply and the second ply. Heating the first ply or the second ply may include heating the first ply or the second ply to a temperature such that the mask coating layer is removed from the first section. The temperature may be up to 1000°C.

[0063] Bending the first ply and the second ply may include bending the first ply and the second ply together. Bending the first ply and the second ply may include bending the first ply and the second ply separately. Bending the plies may occur during heating. The bent first ply and the bent second ply may be joined together to form the automotive transparency in any manner in which two plies are typically joined to form an automotive transparency.

[0064] The interlayer may be disposed between the first and second plies, or may be disposed between the first and second plies before bonding the first and second plies together, or after the first ply is heated and bent, or after the second ply is heated and bent, or after the first and second plies are heated and bent. The interlayer may be any desired material and may include one or more layers or plies. The interlayer may be a polymer or plastic material, such as a multilayer thermoplastic material including, for example, polyvinyl butyral, plasticized polyvinyl chloride, or polyethylene terephthalate. Suitable interlayer materials are disclosed, for example, in U.S. Patent Nos. 4,287,107 and 3,762,988. The interlayer may secure the first and second plies together, provide energy absorption, reduce noise, and improve the strength of the laminate structure. Alternatively, the first and second plies may be bonded together by other means. The interlayer may also be a sound absorbing or damping material, for example, as described in U.S. Patent No. 5,796,055. The interlayer may have a functional coating layer provided thereon or incorporated therein, or may include a coloring material to reduce solar energy transmittance and / or provide color to the transparency. In one non-limiting embodiment, the interlayer may be polyvinyl butyral and may have a thickness in the range of 0.5 mm to 1.5 mm, for example, in the range of 0.75 mm to 0.8 mm (see FIG. 5).

[0065] The invention further includes the subject matter of the following clauses.

[0066] Clause 1: A substrate having a flammable coating mask, the substrate having a first surface and a second surface opposite the first surface; the first surface having a first section and a second section adjacent to the first section; a mask coating layer on the first section, the mask coating layer being not disposed on the second section; and a functional coating layer on at least a portion of the mask coating layer and on the second section.

[0067] Clause 2: The substrate of clause 1, further comprising a temporary protective layer over at least a portion of the functional coating layer.

[0068] Clause 3: The substrate of clause 1 or 2, wherein the substrate comprises a glass sheet.

[0069] Clause 4: The substrate of any of clauses 1-3, wherein the mask coating layer is in direct contact with the substrate.

[0070] Clause 5: The substrate of any of clauses 1-4, wherein the mask coating layer comprises at least one of a wax, an organic oil, a (meth)acrylate, a polyolefin, a polyester, a polycarbonate, a polyether, a polyurethane material, an epoxide material, a polyurea material, or a combination thereof.

[0071] Clause 6: The substrate of clause 5, wherein the mask coating layer comprises at least one of polylactic acid (PLA), polyethylene carbonate (PEC), polypropylene carbonate (PPC), polycaprolactone, polyoxymethylene, polyethylene, polypropylene, water-based polyurethane, polyurethane formed from a two-component system, epoxy-functional polymer material, or a combination thereof.

[0072] Clause 7: The substrate of any of clauses 2-6, wherein the temporary protective layer comprises at least one of a wax, an organic oil, a (meth)acrylate, a polyolefin, a polyester, a polycarbonate, a polyether, or a combination thereof.

[0073] Clause 8: The substrate of any of clauses 1-7, wherein the mask coating layer further comprises additional components including a plasticizer, a crosslinker, a viscosity modifier, a corrosion inhibitor, an infrared (IR) absorber, an adhesion modifier, a UV absorber, a pigment, a surfactant, a hydrophobic agent, or a combination thereof.

[0074] Clause 9: The substrate of any of clauses 1 to 8, wherein the mask coating layer is removable by burning at a temperature of up to 1000°C.

[0075] Clause 10: The substrate of any of clauses 1-9, wherein the mask coating layer is configured to be removable by a heat treatment process without causing substantial damage to the first section.

[0076] Clause 11: The substrate of any of clauses 1-10, further comprising a protective layer disposed over at least a portion of the functional coating layer.

[0077] Clause 12: The substrate of clause 11, wherein the protective layer is selected from the group consisting of metal oxides or metal nitrides.

[0078] Clause 13: A method of segmenting a substrate having a layer thereon, comprising: providing a substrate having a flammable coating mask; a substrate having a first surface and a second surface opposite the first surface; the first surface having a first section and a second section adjacent to the first section; a mask coating layer on the first section, the mask coating layer not being disposed on the second section; a functional coating layer on at least a portion of the mask coating layer and on the second section; providing a substrate having a flammable coating mask, heating the substrate with the flammable coating mask such that the mask coating layer and a portion of the functional coating layer disposed on the mask coating layer are removed from the first section; Includes:

[0079] Clause 14: The method of clause 13, wherein the substrate having the flammable coating mask further comprises a temporary protective layer over at least a portion of the functional coating layer, and wherein said heat treatment removes the temporary protective layer from the functional coating layer.

[0080] Clause 15: The method of clause 13 or 14, wherein the substrate comprises a glass sheet.

[0081] Clause 16: The method of any of clauses 13-15, wherein the mask coating layer is in direct contact with the substrate.

[0082] Clause 17: The method of any of clauses 13-16, wherein the mask coating layer comprises at least one of a wax, an organic oil, a (meth)acrylate, a polyolefin, a polyester, a polycarbonate, a polyether, a polyurethane material, an epoxide material, a polyurea material, or a combination thereof.

[0083] Clause 18: The method of clause 17, wherein the mask coating layer comprises at least one of polylactic acid (PLA), polyethylene carbonate (PEC), polypropylene carbonate (PPC), polycaprolactone, polyoxymethylene, polyethylene, polypropylene, water-based polyurethane, polyurethane formed from a two-component system, epoxy-functional polymer material, or a combination thereof.

[0084] Clause 19: The method of any of clauses 14-18, wherein the temporary protective layer comprises at least one of a wax, an organic oil, a (meth)acrylate, a polyolefin, a polyester, a polycarbonate, a polyether, or a combination thereof.

[0085] Clause 20: The method of any of clauses 13-19, wherein the mask coating layer further comprises additional components including a plasticizer, a crosslinker, a viscosity modifier, a corrosion inhibitor, an infrared (IR) absorber, an adhesion modifier, a UV absorber, a pigment, a surfactant, a hydrophobic agent, or a combination thereof.

[0086] Clause 21: The method of any of clauses 13-20, wherein the heating step includes heating the substrate having the flammable coating mask at a temperature of up to 1000°C.

[0087] Clause 22: The method of any of clauses 13-21, further comprising a protective layer disposed over at least a portion of the functional coating layer.

[0088] Clause 23: The method of Clause 22, wherein the protective layer is selected from the group consisting of metal oxides or metal nitrides.

[0089] Clause 24: The method of any of clauses 13 to 23, wherein the mask coating layer is configured to be removable by a heat treatment without causing substantial damage to the first section.

[0090] Clause 25: A method of preparing a segmented substrate having a layer thereon, comprising: providing a substrate having a first surface and a second surface opposite the first surface, the first surface having a first section and a second section adjacent to the first section; applying a material onto the first section to form a mask coating layer, the mask coating layer not being applied onto the second section; applying a material; applying a functional coating layer over at least a portion of the mask coating layer and over the second section to form a functional coating layer; Includes:

[0091] Clause 26: The method of Clause 25, further comprising applying a second material over at least a portion of the functional coating layer to form a temporary protective layer.

[0092] Clause 27: The method of clause 25 or 26, wherein the substrate comprises a glass sheet.

[0093] Clause 28: The method of any of clauses 25-27, wherein the mask coating layer is in direct contact with the substrate.

[0094] Clause 29: The method of any of clauses 25-28, wherein the mask coating layer comprises at least one of a wax, an organic oil, a (meth)acrylate, a polyolefin, a polyester, a polycarbonate, a polyether, a polyurethane material, an epoxide material, a polyurea material, or a combination thereof.

[0095] Clause 30: The method of clause 29, wherein the mask coating layer comprises at least one of polylactic acid (PLA), polyethylene carbonate (PEC), polypropylene carbonate (PPC), polycaprolactone, polyoxymethylene, polyethylene, polypropylene, water-based polyurethane, polyurethane formed from a two-component system, epoxy-functional polymer material, or a combination thereof.

[0096] Clause 31: The method of any of clauses 26-30, wherein the temporary protective layer comprises at least one of a wax, an organic oil, a (meth)acrylate, a polyolefin, a polyester, a polycarbonate, a polyether, or a combination thereof.

[0097] Clause 32: The method of any of clauses 25-31, wherein the mask coating layer further comprises additional components including a plasticizer, a crosslinker, a viscosity modifier, a corrosion inhibitor, an infrared (IR) absorber, an adhesion modifier, a UV absorber, a pigment, a surfactant, a hydrophobic agent, or a combination thereof.

[0098] Clause 33: The method of any of clauses 25 to 32, further comprising applying a heat treatment to the substrate having the flammable coating mask at a temperature of up to 1000°C.

[0099] Clause 34: The method of any of clauses 25 to 33, wherein the mask coating layer is configured to be removable by a thermal treatment without causing substantial damage to the first section.

[0100] Clause 35: The method of any of clauses 25-34, further comprising a protective layer disposed over at least a portion of the functional coating layer.

[0101] Clause 36: The method of Clause 35, wherein the protective layer is selected from the group consisting of silicon nitride, Si3N4, SiAlN, SiAlON, titania, alumina, silica, zirconia, tin oxide, mixtures thereof, and alloys thereof.

[0102] Clause 37: The method of any of clauses 25 to 36, wherein the second material is different from the first material.

[0103] Clause 38: The method of any of clauses 25 to 36, wherein the second material is the same as the material.

[0104] Clause 39: A segmented substrate prepared by the following steps: providing a substrate having a flammable coating mask; a substrate having a first surface and a second surface opposite the first surface; the first surface having a first section and a second section adjacent to the first section; a mask coating layer on the first section, the mask coating layer not being disposed on the second section; a functional coating layer on at least a portion of the mask coating layer and on the second section; providing a substrate having a flammable coating mask, A step of heating the substrate having the flammable coating mask, the step of heating the substrate having the flammable coating mask such that the mask coating layer and a portion of the functional coating disposed on the mask coating layer are removed from the first section.

[0105] Clause 40: The segmented substrate of clause 41, wherein the substrate having the flammable coating mask further comprises a temporary protective layer over at least a portion of the functional coating layer, and wherein said heat treatment removes the temporary protective layer.

[0106] Clause 41: The segmented substrate of clause 39 or 40, wherein the substrate comprises a glass sheet.

[0107] Clause 42: The segmented substrate of any of clauses 39-41, wherein the mask coating layer is in direct contact with the substrate.

[0108] Clause 43: The segmented substrate of any of clauses 39 to 42, wherein the mask coating layer comprises at least one of a wax, an organic oil, a (meth)acrylate, a polyolefin, a polyester, a polycarbonate, a polyether, a polyurethane material, an epoxide material, a polyurea material, or a combination thereof.

[0109] Clause 44: The segmented substrate of clause 43, wherein the mask coating layer comprises at least one of polylactic acid (PLA), polyethylene carbonate (PEC), polypropylene carbonate (PPC), polycaprolactone, polyoxymethylene, polyethylene, polypropylene, water-based polyurethane, polyurethane formed from a two-component system, epoxy-functional polymer material, or a combination thereof.

[0110] Clause 45: The segmented substrate of any of clauses 40-44, wherein the temporary protective layer comprises at least one of a wax, an organic oil, a (meth)acrylate, a polyolefin, a polyester, a polycarbonate, a polyether, or a combination thereof.

[0111] Clause 46: The segmented substrate of any of clauses 39 to 45, wherein the mask coating layer further comprises additional components including a plasticizer, a crosslinker, a viscosity modifier, a corrosion inhibitor, an infrared (IR) absorber, an adhesion modifier, a UV absorber, a pigment, a surfactant, a hydrophobic agent, or a combination thereof.

[0112] Clause 47: The segmented substrate of any of clauses 39 to 46, wherein the heat treatment comprises heating the substrate having the flammable coating mask at a temperature of up to 1000°C.

[0113] Clause 48: The segmented substrate of any of clauses 39 to 47, wherein the mask coating layer is configured to be removable by a thermal treatment without causing substantial damage to the first section.

[0114] Clause 49: The segmented substrate of any of clauses 39 to 48, further comprising a protective layer disposed over at least a portion of the functional coating layer.

[0115] Clause 50: The method of Clause 49, wherein the protective layer is selected from the group consisting of silicon nitride, Si3N4, SiAlN, SiAlON, titania, alumina, silica, zirconia, tin oxide, mixtures thereof, and alloys thereof.

[0116] Clause 51: A method for preparing a vehicle transparency, comprising: providing a first ply having a No. 1 surface and a No. 2 surface opposite the No. 1 surface; providing a second ply having a No. 3 surface and a No. 4 surface opposite the No. 3 surface; applying a flammable coating mask to a first section of the No. 1 surface, the No. 2 surface, the No. 3 surface, or the No. 4 surface, wherein the flammable coating mask is not applied to a second section of the No. 1 surface, the No. 2 surface, the No. 3 surface, or the No. 4 surface; applying a functional coating layer over at least a portion of the mask coating layer and over the second section; simultaneously or separately heating the first ply and the second ply; bonding the first ply and the second ply together to form an automotive transparency; A method comprising:

[0117] Clause 52: The method of clause 51, further comprising simultaneously or separately bending the first ply and bending the second ply.

[0118] Clause 53: The method of clause 51 or 52, wherein the first ply and the second ply are heated separately.

[0119] Clause 54: The method of clause 52 or clause 53, wherein the first ply and the second ply are bent separately.

[0120] Clause 55: The method of any of clauses 51-54, further comprising disposing an intermediate layer between the first ply and the second ply.

[0121] Clause 56: The method of any of clauses 51 to 55, wherein the step of heating the second ply includes heating the second ply to a temperature such that the mask coating layer and a portion of the functional coating disposed on the mask coating layer are removed from the first section.

[0122] Clause 57: The method of clause 56, wherein the temperature is at most 1000°C.

[0123] Clause 58: A method for preparing a vehicle transparency, comprising: providing a ply having a first major surface and a second major surface opposite the first major surface, the first major surface including a first section and a second section adjacent to the first section, a mask coating layer disposed on the first section, the mask coating layer not disposed on the second section, and a functional coating layer disposed on a portion of the mask coating layer and on the second section; heating the ply, whereby the mask coating layer and a portion of the functional coating layer disposed on the mask coating layer are removed from the first section; bending the ply; Includes:

[0124] Clause 59: The method of clause 58, wherein the temperature is at most 1000°C.

[0125] The following examples are presented to demonstrate the general principles of the invention of this disclosure, and the invention should not be considered limited to the specific examples presented. [Example]

[0126] The coated substrate containing the mask coating layer was prepared according to the following procedure. A 12" x 12" 6mm thick transparent glass substrate was prepared. The glass substrate was cleaned in an industrial washer. An epoxy acrylate UV-curable resin was diluted with acetone to a 50:50 ratio. The diluted epoxy acrylate UV-curable resin was applied to a small area on the surface of the glass substrate using a dropper. The small area of ​​the diluted epoxy acrylate UV-curable resin was allowed to dry, and then 250-300mJ / cm was applied. 2The mask coating layer was then cured using ultraviolet light with an energy density of 1000 Hz to produce a mask coating layer. The thickness of the mask coating layer ranged from 7 to 10 μm. The glass substrate with the mask coating layer was then cleaned again in an industrial cleaning machine. After cleaning, the glass substrate with the mask coating layer was placed in a pilot coater, and a Solarban® 60VT Double Silver functional coating was deposited on the glass substrate and the mask coating layer to produce a coated substrate. The coated substrate was then placed in a box furnace set at a temperature of 700°C (1292°F). The coated substrate was heated in the box furnace until it reached a glass temperature of approximately 1180°F (approximately 640°C). The coated substrate was then removed from the box furnace and allowed to cool to room temperature (i.e., between 20 and 30°C). Figure 6 is a micrograph of the coated substrate taken after it was removed from the box furnace and cooled to room temperature. As shown in Figure 6, the areas containing the mask coating layer below the functional coating (i.e., the bottom and left regions) were removed during heating in the box furnace. Outside the area containing the mask coating layer (i.e., the top and right areas), the functional coating remained intact. A small amount of debris is visible at the boundary between the area of ​​the coated substrate containing the mask coating layer and the area not containing the mask coating layer. The coated substrate was washed in an industrial washer to remove any remaining debris of the mask coating layer and / or functional coating remaining after heating. Thus, this example effectively demonstrates the ability of the present invention to produce a coated substrate containing a functional coating on a first area of ​​the substrate and not containing a functional coating on a second area of ​​the substrate.

[0127] While the present invention has been described in detail for purposes of illustration based on what are presently considered to be the most practical and preferred embodiments, it should be understood that such detail is for that purpose only and that the invention is not limited to the disclosed embodiments, but rather is intended to cover modifications and equivalent arrangements within the spirit and scope of the appended claims. For example, it should be understood that the present invention contemplates that one or more features of any embodiment can be combined, to the extent possible, with one or more features of any other embodiment.

Claims

1. A process for preparing a segmented substrate, comprising: The process is Providing a substrate having a flammable coating mask, the substrate having the flammable coating mask comprising: a substrate having a first surface and a second surface opposite the first surface, the first surface having a first section and a second section adjacent to the first section; a mask coating layer on the first section and not disposed on the second section; a functional coating layer over at least a portion of the mask coating layer and over the second section; a protective layer disposed over at least a portion of the functional coating layer; providing a substrate having a flammable coating mask, heating the substrate with the flammable coating mask such that the mask coating layer and a portion of the functional coating disposed on the mask coating layer are removed from the first section; is a process including the mask coating layer comprises at least one of a wax, an organic oil, a polyolefin, a polyester, a polycarbonate, a polyether, a water-based polyurethane, a polyurethane formed from a two-component system, a polyurea material, or a combination thereof; the protective layer is selected from the group consisting of silicon nitride, Si3N4, SiAlN, SiAlON, titania, alumina, silica, zirconia, tin oxide, mixtures thereof, and alloys thereof; The above process.

2. The process of claim 1 , wherein the substrate having the flammable coating mask further comprises a temporary protective layer over at least a portion of the functional coating layer, and the heat treatment removes the temporary protective layer.

3. The process of claim 1 , wherein the substrate comprises a glass sheet.

4. The process of claim 1 , wherein the mask coating layer is in direct contact with the substrate.

5. 10. The process of claim 1, wherein the mask coating layer comprises at least one of polylactic acid (PLA), polyethylene carbonate (PEC), polypropylene carbonate (PPC), polycaprolactone, polyoxymethylene, polyethylene, polypropylene, or combinations thereof.

6. The process of claim 2 , wherein the temporary protective layer comprises at least one of a wax, an organic oil, a (meth)acrylate, a polyolefin, a polyester, a polycarbonate, a polyether, or a combination thereof.

7. 10. The process of claim 1, wherein the mask coating layer further comprises additional components including a plasticizer, a crosslinker, a viscosity modifier, a corrosion inhibitor, an infrared (IR) absorber, an adhesion modifier, a UV absorber, a pigment, a surfactant, a hydrophobic agent, or a combination thereof.

8. 10. The process of claim 1, wherein the heat treatment comprises heating the substrate having the flammable coating mask at a temperature of up to 1000[deg.]C.

9. The process of claim 1 , wherein the mask coating layer is configured to be removable by the heat treatment without substantially damaging the first section.

10. A transparent body, The transparent body is a first ply having a number 1 surface and a number 2 surface opposite the number 1 surface; a second ply having a number 3 surface and a number 4 surface opposite the number 3 surface; at least one intermediate layer located between the number 2 and number 3 surfaces, the intermediate layer being designed to bond the first ply to the second ply; Including, At least one of the first ply or the second ply is a segmented substrate formed from a substrate having a flammable coating mask; The segmented substrate comprises: a substrate having a first surface and a second surface opposite the first surface, the first surface of the substrate having a first section and a second section adjacent to the first section; a flammable mask coating layer on the first section, the flammable mask coating layer being absent on the second section; a functional coating layer on at least a portion of the mask coating layer and on the second section; Including, the flammable mask coating layer is removed via a heat treatment such that the mask coating layer is removed from the first section, a first portion of the functional coating disposed on at least a portion of the mask coating layer is removed, and a second portion of the functional coating layer disposed on the second section remains on the substrate, resulting in a segmented substrate forming at least one of the first ply or the second ply; the mask coating layer comprises at least one of a wax, an organic oil, a polyolefin, a polyester, a polycarbonate, a polyether, a water-based polyurethane, a polyurethane formed from a two-component system, a polyurea material, or a combination thereof; The transparent body mentioned above.

11. 11. The transparency of claim 10, wherein the mask coating layer comprises at least one of polylactic acid (PLA), polyethylene carbonate (PEC), polypropylene carbonate (PPC), polycaprolactone, polyoxymethylene, polyethylene, polypropylene, or combinations thereof.

12. 11. The transparency of claim 10, wherein the mask coating layer is removable by burning at temperatures up to 1000°C.

13. A substrate having a flammable coating mask, The substrate having the flammable coating mask is a substrate having a first surface and a second surface opposite the first surface, the first surface including a first section and a second section adjacent to the first section; a mask coating layer on the first section and not on the second section; a functional coating layer over at least a portion of the mask coating layer and over the second section; Including, the mask coating layer comprises at least one of a wax, an organic oil, a polyolefin, a polyester, a polycarbonate, a polyether, a water-based polyurethane, a polyurethane formed from a two-component system, a polyurea material, or a combination thereof; the mask coating layer comprises at least one of polylactic acid (PLA), polyethylene carbonate (PEC), polypropylene carbonate (PPC), polycaprolactone, polyoxymethylene, polyethylene, polypropylene, or a combination thereof; A substrate having the above flammable coating mask.

Images