Foldable panel

Abstract

The invention relates to a foldable panel arrangement (1) having rigid and flexible regions, wherein the rigid regions are formed as rigid shaped elements (2), preferably made of glass, and a joint region (3) made of flexible joint material is formed between the shaped elements (2), and the shaped elements (2) are connected to the joint material in a materially bonded manner via at least one connecting section (4), wherein the panel arrangement (1) further comprises three or more rigid shaped elements (2) which are connected to one another via flexible joint regions (3) and the panel arrangement (1) is reversibly foldable in two or more spatial directions, at least from a first end position to a second end position. The invention also relates to a method for producing such a reversibly foldable panel arrangement (1).

Description

[0001] FOLDABLE DISC

[0002] The invention relates to a foldable disc arrangement and a method for its production and its use.

[0003] Laminated glass panels are used in a wide variety of applications, such as architecture, building components, automotive, security technology, smart technology, and household appliances, and are being equipped with an increasing number of functionalities. High demands are often placed on safety, but also on appearance and design, as well as the greatest possible adaptability of the laminated glass to the surroundings or the supporting element, product, spatial conditions, or the object equipped with the laminated glass, be it a building or a vehicle, for example. Glass constructions are enjoying increasing popularity in architecture. Structural glass applications are just as possible as the combination of different glass products to improve specific functions.However, opening and closing mechanisms and associated spatial requirements often play a major role, which would require the mobility and flexibility of an insertable composite pane, which cannot yet be provided.

[0004] The object of the present invention is therefore to provide a pane assembly that can meet these requirements, offers increased flexibility in its usability and spatial adaptability, and is movable and flexible in at least one spatial direction, allowing it to be used adaptably, for example, in openings in objects. Furthermore, the pane assembly should be visually appealing and as simple and cost-effective to manufacture as possible.

[0005] These and other objects are achieved according to the invention by a disk arrangement according to claim 1 and a method according to claim 11. Preferred embodiments emerge from the subclaims.

[0006] According to the invention, a pane arrangement with rigid and flexible regions is provided, wherein the rigid regions are formed from rigid shaped elements, preferably from glass, and a joint region made from flexible joint material is formed between the shaped elements and the shaped elements are materially connected to the joint material via at least one connecting section, wherein the pane arrangement (1) further comprises three or more rigid shaped elements (2) which are connected to one another via flexible joint regions (3) and the pane arrangement (1) is reversibly foldable in two or more spatial directions, at least from a first end position to a second end position.

[0007] In other words, the pane arrangement according to the invention is reversibly foldable, for example, from a flat first end position (initial position), in two or more spatial directions, at least into a second, folded end position. The pane arrangement can therefore also be transferred from the second, folded end position at least into the initial position.

[0008] Surprisingly, it is even possible to design the disc arrangement according to the invention with the rigid shaped elements and flexible joint regions in such a way that it can be transferred from a substantially flat, planar starting position, which represents a first end position, into a multiply folded, three-dimensional second end position according to a predetermined origami folding pattern. It is therefore possible to obtain aesthetically, functionally, and spatially sophisticated end positions of the disc arrangement, and optionally, through the folding, for example, advantageously very space-saving. It is intended that the folds of the disc arrangement are reversible, i.e., they can be transferred from the formed second end position back into the, for example, substantially planar, starting position.

[0009] Rigid shaped elements are provided to impart the necessary strength to the pane arrangement according to the invention. The shape and design of the shaped elements furthermore essentially determine the appearance and at least partially the possible end position shapes of the pane arrangement and their space requirements in the end positions. In other words, the shaped elements can advantageously be selected to match a desired design and a possibly desired or predetermined end position, a folding pattern and / or shape of the pane arrangement. Adaptation or selection of the specific design of the shaped elements used for the pane arrangement can advantageously also be carried out with regard to necessary or required safety aspects and standards, for example in the choice of material, the thickness and dimensions as well as the arrangement of the shaped elements within the pane arrangement.The shaped elements of the disc arrangement can, for example, be made independently of one another from the same or from different materials.

[0010] The molded elements are bonded to the joint material in a material-to-material manner, creating a permanent connection. The molded elements are spaced apart from each other by the joint area and are designed, for example, like hinges, at least pivotable (foldable) relative to each other.

[0011] The molded elements are preferably made of glass, for example, flat glass, float glass, quartz glass, borosilicate glass, soda-lime glass, or aluminosilicate glass. The molded elements can also be made of single-pane safety glass or a glass composite.

[0012] In another preferred embodiment, the disc arrangement can be reversibly folded steplessly and continuously, or alternatively in two or more stages, into one or more predefined intermediate positions, adjustable from at least a first end position to a second end position. The intermediate positions can also be referred to as intermediate end positions. When adjustable in stages, the disc arrangement can thus assume, for example, three, four, or five predefined (intermediate) end positions. The number of stages and the resulting folding positions / positions of the disc arrangement are to be understood as examples only and are not exhaustive.

[0013] In a preferred embodiment, the shaped elements and / or the flexible joint region of the pane arrangement are transparent. Thus, for example, it is possible for either the shaped elements to be transparent or for the flexible joint regions to be formed from a transparent joint material. In a preferred alternative, both the shaped elements and the joint regions are transparent, preferably resulting in an overall transparent pane arrangement.

[0014] For the purposes of the present invention, "transparent" means that the total visible light transmission of the composite pane is preferably more than 50%, and in particular more than 60%, for example more than 70%. "Transparent shaped element" and "transparent hinge area" thus mean that they are transparent enough to achieve the desired or necessary transparency for the respective intended use. Accordingly, "opaque" means a light transmission of less than 10%, preferably less than 5%, and in particular 0%. Light transmission is measured according to ISO 9050:2003.

[0015] In another preferred embodiment, the flexible joint areas are at least partially tinted, colored, or printed. This can create a visually appealing appearance, for example, through an attractive pattern of the formed joint areas, and can also enhance the appearance by concealing cables or adhesives, for example.

[0016] According to another embodiment, the shaped elements and the joint regions are made of a material with an average refractive index n between 1.4 and 1.6 in the spectral range optically visible to humans at wavelengths from 380 nm to 780 nm. The refractive index, also called refractive index or refractive coefficient, is a unitless material constant that specifies the ratio of the speed of light in a vacuum to the speed of propagation of light in a medium. The materials of the shaped elements and the joint regions therefore particularly preferably have an average refractive index n that is as similar as possible to that of glass. For example, the average refractive index for the visible spectral range (380 nm to 780 nm) is approximately 1.5 for commercially available soda-lime silicate glass, approximately 1.47 for borosilicate glass, and approximately 1.5 for aluminosilicate glass.Particularly, and expediently, when the shaped elements are made of glass, it is preferable to form the joint regions with a material with a refractive index that is as similar as possible to that of the glass. The joint regions preferably have a refractive index n that differs from the refractive index n of the selected shaped elements in the visible spectral range (380 nm to 780 nm) by less than 0.1, for example, less than 0.05. This is particularly advantageous because no light refraction or reflection occurs at the interfaces of the materials used, giving the pane arrangement a particularly uniform and aesthetically pleasing appearance.In a preferred embodiment, the flexible joint material is an optically transparent adhesive (OCA), for example based on acrylate or silicone, a polyvinyl butyral (PVB), ethylene-vinyl acetate (EVA), and / or polyurethane (PU), or copolymers or derivatives thereof, optionally in combination with polyethylene terephthalate (PET). However, the joint material can also contain, for example, polypropylene (PP), polyacrylate, polyethylene (PE), polycarbonate (PC), polymethyl methacrylate, polyvinyl chloride, polyacetate resin, acrylate, fluorinated ethylene-propylene, polyvinyl fluoride, and / or ethylene-tetrafluoroethylene, or a copolymer or mixture thereof. The joint material can be used as a thermoplastic film or as a flexible carrier film in the manufacture of the disc assembly.

[0017] The joint material may contain additives known to those skilled in the art, such as plasticizers, to permanently maintain the required flexibility for the foldability of the disc assembly. Preferably, the joint material contains at least one plasticizer.

[0018] Plasticizers are chemical compounds that make plastics softer, more flexible, more supple and / or more elastic. They shift the thermoelastic range of plastics towards lower temperatures so that the plastics exhibit the desired more elastic properties near the application temperature. Preferred plasticizers are carboxylic acid esters, particularly low-volatility carboxylic acid esters, fats, oils, plastic resins and camphor. Other plasticizers are preferably aliphatic diesters of tri- or tetraethylene glycols. Particular preference is given to using plasticizers 3G7, 3G8 or 4G7, where the first digit indicates the number of ethylene glycol units and the last digit indicates the number of carbon atoms in the carboxylic acid moiety of the compound. For example, 3G8 stands for triethylene glycol bis(2-ethylhexanoate), i.e. a compound with the formula C4H9CH(CH2CH3)CO(OCH2CH2)3O2CCH(CH2CH3)C4H9.

[0019] For example, a joint material, such as a thermoplastic PVB film, based on PVB contains at least 3% by weight, preferably at least 5% by weight, particularly preferably at least 20% by weight, even more preferably at least 30% by weight, and in particular at least 35% by weight of a plasticizer. The plasticizer contains or consists, for example, of triethylene glycol bis(2-ethylhexanoate). The rigid molded elements of the pane arrangement according to the invention are particularly preferably made of glass. In further preferred embodiments, however, they can also be formed from known, glass-like rigid plastics, such as polycarbonate (PC), polymethyl methacrylate (PMMA), polyurethane (PU), polyethylene (PE), polypropylene (PP), polystyrene, polyamide, polyester, polyvinyl chloride, and / or mixtures thereof.

[0020] It is therefore possible that both the rigid mold elements and the flexible joint areas are formed on the basis of the same material, for example from the aforementioned plastics as the main component (base material), and if necessary the foldability is created via appropriate additives or merely a thickness adjustment, for example a thinner design in the joint area in relation to the mold element.

[0021] In a further embodiment, the shaped elements are designed with identical or different, regular and / or irregular geometric shapes, surfaces, and cross-sections. This allows for great design variability and, in particular, also for the possibilities in the spatial configuration and foldability of the panel arrangement.

[0022] In another embodiment, the rigid shaped elements can be independently formed in regular or irregular geometric shapes, in particular as triangles, quadrilaterals, squares, parallelograms, trapezoids, rhombuses, pentagons, hexagons, and / or octagons, and / or in rounded or circular geometries. Identical or different shaped elements with different geometries, surfaces, thicknesses, cross-sections, and / or sizes can be used within a disc arrangement.

[0023] In one embodiment of the disc arrangement according to the invention, the shaped elements can be at least partially positioned and arranged in a matrix of joint material. In one embodiment, the shaped elements can thus be completely enclosed by joint material. Alternatively, the shaped elements can also protrude from the matrix of joint material, i.e., be only partially incorporated into the joint material. The joint material can also be arranged exclusively between the rigid shaped elements and be integrally connected to them, for example, via an edge of each of the shaped elements as a connecting section, thus forming the joint region.

[0024] The shaped elements can also be arranged on one or both sides of the surface of a flexible carrier film, which serves as the joint material, and connected to it in a material-to-material manner, for example by bonding with an optically clear adhesive. The shaped elements can be arranged in a two-sided arrangement on the opposite surfaces of a carrier film in a plan view of the pane arrangement, overlapping, for example, in particular congruently, given the same shape and dimensions. This can result in a sandwich-like structure in these areas in cross-section, for example glass-PVB-film-glass, as in a laminated pane. A non-overlapping or only partially overlapping arrangement in plan view, or an asymmetrical cross-section, for example due to a different thickness of the shaped elements, is also conceivable.This further increases the possible design freedom in the function, shape and appearance of the pane arrangement.

[0025] In another preferred embodiment of the invention, it is provided that the disc arrangement is connected to at least one holding device and / or to fastening means and / or to a movement device.

[0026] Mounting devices can, for example, be support structures and supporting elements that can carry and support the composite pane in a final position according to the application requirements. However, they can also be rails, guides, and the like into which the edge regions of the pane assembly can be at least partially accommodated, which then provide appropriate support and securing both during the folding process and / or in the final positions of the pane assembly.

[0027] Fastening means can be, for example, eyelets, hooks, clamps, screws, rivets, wires, or ropes. These can, for example, be firmly connected to the shaped elements and / or in the joint area and serve to attach a mechanism as a movement device to effect or simply to support the reversible folding of the disc arrangement. The invention further comprises a method for producing a foldable disc arrangement with rigid and flexible regions as described above in various embodiments, wherein the method comprises the steps of a) providing at least three rigid shaped elements, b) materially connecting connecting sections of the shaped elements to a joint material to form at least one flexible joint area between the shaped elements.

[0028] In one embodiment of the method, the mold elements are arranged on a thermoplastic film or between two thermoplastic films of joint material for bonding and are then bonded together under heat, vacuum and / or pressure to form the disc arrangement in the manner of a composite disc.

[0029] The connection can be achieved, for example, by laminating the layer stack of molded elements and at least one thermoplastic film as joint material under the influence of heat, vacuum and / or pressure, whereby the individual molded parts are integrally bonded (laminated) to the joint material. For example, known processes for producing a composite pane can be used. For example, so-called autoclave processes can be carried out at an elevated pressure of approximately 10 bar to 15 bar and temperatures of 130 °C to 145 °C for approximately 2 hours. Known vacuum bag or vacuum ring processes operate, for example, at approximately 200 mbar and 130 °C to 145 °C. The molded elements and thermoplastic film as joint material can also be pressed into a composite pane in a calender between at least one pair of rollers.Systems of this type are known for the production of laminated glass and typically have at least one heating tunnel upstream of a press unit. The temperature during the pressing process, for example, ranges from 40°C to 150°C. Combinations of calendering and autoclave processes have proven particularly effective in practice. Alternatively, vacuum laminators can be used. These consist of one or more heatable and evacuatable chambers in which the outer and inner panes can be laminated within, for example, approximately 60 minutes at reduced pressures of 0.01 mbar to 800 mbar and temperatures of 80°C to 170°C. These specifications are only examples.

[0030] Another embodiment of the method provides for the thermoplastic film of joint material to be inserted in one piece or in multiple pieces. This makes it possible, for example, to form sub-regions of the pane assembly with different thicknesses or with different material properties, such as different flexibility, elasticity, or tear resistance, as needed. Furthermore, pre-colored or tinted joint material can be used for the areas forming the joint region.

[0031] In an alternative embodiment of the method, a liquid optically clear adhesive (LOGA) or a casting resin is used as the joint material, and the molded elements are each connected to one another via at least one edge as a connecting section, forming a joint region, or the molded elements are positioned in this liquid adhesive or casting resin, at least partially absorbed therein, and bonded together. Suitable optically transparent adhesives and casting resins for bonding molded elements, particularly those made of glass, and their handling to produce a bonded connection are known per se.

[0032] In an alternative embodiment of the process, the molded elements are arranged on one or both sides of a flexible carrier film as the joint material and are bonded to the surface of the carrier film in a material-to-material bond, preferably by adhesive bonding, forming at least one joint area. Bonding can be achieved in a conventional manner using an optically clear adhesive. If the carrier film is thermoplastic, the material-to-material bond can also be achieved directly with the carrier film by applying heat and / or pressure.

[0033] The invention also encompasses the use of a foldable pane arrangement, as described above in various embodiments, in the field of architecture, in buildings, parts of buildings, vehicles, and household items, although this list is not exhaustive. The various embodiments of the invention can be implemented individually or in any combination. In particular, the features mentioned above and those to be explained below can be used not only in the specified combinations, but also in other combinations or on their own, without departing from the scope of the present invention. These possible combinations also apply to features mentioned in connection with the pane arrangement and to features described for the method.

[0034] The invention is explained in more detail below using exemplary embodiments, with reference to the accompanying figures. They show, in simplified form and not to scale:

[0035] Figure 1 is a schematic plan view of an exemplary embodiment of the foldable disc arrangement according to the invention;

[0036] Figures 2a-2d each show a cross-sectional view along the section line XX' in various embodiments of the disc arrangement from Figure 1 in a first end position;

[0037] Figure 3 is a cross-sectional view of the disc arrangement of Fig. 2a in folding;

[0038] Figure 4 is a schematic plan view of another embodiment of the disc arrangement according to the invention;

[0039] Figure 5 Photo detail of a disc arrangement according to the invention according to the

[0040] Embodiment in Figure 4;

[0041] Figure 6 shows an example of a possible pattern for an origami-like foldable disc arrangement 1 according to the invention.

[0042] Figure 1 shows a schematic plan view of an exemplary embodiment of the foldable pane arrangement 1 according to the invention in a first flat end position, which can also be referred to as the unfolded starting position. In this embodiment, the pane arrangement 1 has, for example, six rigid shaped elements 2 with a quadrangular geometry, more precisely in the form of parallelograms. The hinge regions 3 run between the shaped elements 2, which are integrally connected to one another with the hinge material, for example made of PVB, used as a thermoplastic film. The shaped elements 2 can be pivoted relative to one another via the hinge regions 3, as schematically represented by the arrows A, A', and A", and a folding of the pane arrangement 1 can be brought about in different spatial directions. The indicated folding in the direction of the arrows A and A' is shown schematically in Figure 3.

[0043] Figures 2a-2d each show a cross-sectional view along the section line XX' in various embodiments of the disc arrangement 1 of Figure 1 in a first end position; which can also be referred to as an unfolded position or unfolded or stretched initial position.

[0044] In Figure 2a, the shaped elements 2 are inserted with one surface flush into the joint material, so that they form a flat surface in this first end position of the disc assembly 1. The material connection is thus established via the edges, i.e., the lateral edges, as well as via a surface as a connecting section.

[0045] In Figure 2b, the shaped elements 2 are partially incorporated into the joint material, with the shaped elements 2 protruding from the joint material at the top, as shown here. Such a disc arrangement can be produced, for example, by placing the shaped elements 2 onto a thermoplastic film and partially pressing them into the film under heat and pressure, thus bonding them to the film in a materially bonded manner, with joint regions 3 being formed between the shaped elements.

[0046] In Figure 2c, the molded elements 2 are arranged on both sides of a carrier film made of joint material. The material connection can be achieved, for example, by bonding, for example, with an optically clear adhesive, across a surface as the connecting section of the molded elements 2.

[0047] In Figure 2d, the shaped elements 2 are connected exclusively via an edge or border section with joint material. Such an embodiment of the disc arrangement 1 can be produced, for example, by surrounding the shaped elements 2, optionally positioned in a casting mold, with a liquid adhesive and creating the material-to-material connection upon curing. The connecting region between the connecting sections 4 at the edges of the shaped elements in this case forms the joint region 3. This joint region 3 can, as shown, have a smaller thickness than the shaped elements 2. The joint material can also be made thinner towards the center of the joint region 3 between the shaped elements 2, with a gradient in thickness (not shown).The shaped elements 2 can also protrude laterally beyond the joint material and, if necessary, serve at least partially to fasten or connect the disc arrangement 1 to movement devices or to holding devices.

[0048] Figure 3 shows a cross-sectional view of the pane assembly 1 of Fig. 1, which has been transferred into a folded position. The position shown does not have to be the second, folded end position of the pane assembly 1, but can be achieved, for example, when the adjacently arranged shaped elements 2 are arranged overlapping, possibly flat on top of one another. The folding in the direction of arrow A is not shown here.

[0049] Figure 4 shows a schematic plan view of another embodiment of the pane assembly 1 according to the invention, in which the shaped elements 2 are designed exclusively as right-angled triangles. Joint regions 3 extend between the triangular shaped elements 2, so that in this embodiment, the pane assembly 1 is foldable three-dimensionally in several spatial directions.

[0050] Figure 5 shows a photographic detail of a disc arrangement according to the invention according to the embodiment in Figure 4. The joint areas 3a and 3b from Figure 4 are also shown here.

[0051] Figure 6 shows an example of a possible pattern for an origami-like foldable disc arrangement 1. The folding can take place from the flat, maximally expanded first end position in a rosette-like manner around the central hexagonal shaped element 2H, whereby the joint regions 3T and 3B, which extend radially outwards, are alternately folded downwards (valley) and upwards (mountain) and then a spiral fold can be carried out from the center outwards. According to this pattern, triangles and trapezoidal surfaces of different shapes and sizes are used as shaped elements 2. On the outer, edge-side shaped elements 2, for example, fastening means can be arranged which can be connected to a mechanism for re-expansion from the folded rosette-like end position.

[0052] According to the invention, a pane arrangement 1 is provided that has increased flexibility in its usability and spatial adaptability, and that is reversibly foldable in at least two spatial directions and thus inherently movable and flexible. The pane arrangement 1 according to the invention can be adapted to the application, for example, in openings of objects. Furthermore, the pane arrangement 1 can be given a visually appealing design, for example, through the selection of the shaped elements 2. Production is simple and cost-effective, and the use of known process steps offers possibilities for integration into industrial series production.

[0053] List of reference symbols

[0054] 1 disc arrangement

[0055] 2 rigid form element 2H central rigid form element

[0056] 3, 3a, 3b joint area

[0057] 3B Joint area folding upwards (mountain)

[0058] 3T joint area folding downwards (valley)

[0059] 4 Connecting section A, A', A" arrows (folding direction)

[0060] XX' cutting line

Claims

Patent claims 1. Disc arrangement (1), characterized in that it has rigid and flexible regions, wherein the rigid regions are formed from rigid shaped elements (2) and a joint region (3) made of flexible joint material is formed between shaped elements (2), and the shaped elements (2) are materially connected to the joint material via at least one connecting section (4), wherein the disc arrangement (1) further comprises three or more rigid shaped elements (2) which are connected to one another via flexible joint regions (3), and the disc arrangement (1) is reversibly foldable in two or more spatial directions, at least from a first end position to a second end position.

2. Disc arrangement (1) according to claim 1, characterized in that it is reversibly foldable, steplessly and continuously or in two or more predefined steps, into one or more intermediate positions, at least from a first end position to a second end position.

3. Disc arrangement (1) according to claim 1 or 2, characterized in that the shaped elements (2) and / or the flexible joint region (3) are transparent.

4. A pane arrangement according to one of claims 1 to 3, characterized in that the shaped elements (2) and the joint regions (3) are made of a material having an average refractive index n in the visible spectral range from 380 nm to 780 nm between 1.4 and 1.

6.

5. A pane arrangement according to any one of claims 1 to 4, characterized in that the flexible joint material is an optically transparent adhesive (OCA), polyvinyl butyral (PVB), ethylene vinyl acetate (EVA), and / or polyurethane.

6. Pane arrangement (1) according to one of claims 1 to 5, characterized in that the shaped elements (2) are made of glass, polycarbonate (PC), polymethyl methacrylate (PMMA) and / or polyurethane (PU).

7. Disc arrangement (1) according to one of claims 1 to 6, characterized in that the shaped elements (2) are formed with identical or different, regular and / or irregular geometric shapes, surfaces and cross sections.

8. Disc arrangement (1) according to one of claims 1 to 7, characterized in that the shaped elements (2) are designed as triangles, quadrilaterals, squares, parallelograms, trapezoids, rhombuses, pentagons, hexagons and / or octagons and / or in rounded or circular surface geometries and / or cross sections.

9. Disc arrangement (1) according to one of claims 1 to 8, characterized in that the shaped elements (2) are at least partially positioned and arranged in a matrix of joint material or the shaped elements (2) are arranged on one or two sides on a flexible carrier film as joint material and are connected to it in a materially bonded manner.

10. Disc arrangement (1) according to one of claims 1 to 9, characterized in that it is connected to at least one holding device and / or fastening means and / or a movement device. 11 .A method for producing a foldable disc arrangement (1) with rigid and flexible areas according to one of claims 1 to 10, characterized by the steps a) providing at least three rigid shaped elements (2) b) materially connecting connecting sections of the shaped elements (2) with a joint material forming at least one flexible joint area (3) between the shaped elements (2).

12. Method according to claim 11, characterized in that the shaped elements (2) are arranged for joining on a thermoplastic film or between two thermoplastic films of joint material and are then joined together to form a joint region (3) to form the disc arrangement (1) under the influence of heat, vacuum and / or pressure.

13. Method according to claim 12, characterized in that the thermoplastic film of joint material is used in one piece or in several pieces.

14. Method according to claim 10, characterized in that the form elements (2) arranged on one or both sides on a flexible carrier film as joint material and connected to this carrier film in a material-locking manner, preferably by gluing, to form at least one joint region (3).

15. Method according to claim 11, characterized in that a liquid optical adhesive or a casting resin is used as the joint material and the shaped elements (2) are each connected to one another via at least one edge as a connecting section (4) to form a joint area (3) or the shaped elements (2) are connected to one another to form at least one joint area (3) be positioned in the joint material, at least partially received therein and firmly bonded thereto.

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