Semi-finished product having a layer structure

Abstract

The invention relates to a semi-finished product (10), said semi-finished product (10) having the following layers: - a substrate layer (14) containing at least one metal; - a functional layer (30) which is designed to generate light, current and / or heat and is provided above the substrate layer (14) in a construction direction (AR), which is perpendicular to the substrate layer (14); - a first thin layer (32) which contains at least one first material (34) and is provided above the functional layer (30); and - a second thin layer (32) which contains at least one second material (38) and is provided above the first thin layer (32), a phase boundary surface (46) being formed between the first thin layer (32) and the second thin layer (36).

Description

[0001] Semi-finished product with layered structure

[0002] Background of the invention

[0003] The invention relates to a semi-finished product with a layered structure. The invention further relates to a method for producing the semi-finished product.

[0004] As an example for the production of layered structures, WO 2023 / 089139 A1 discloses a method for producing a cover unit for a solar module, in which a planar cover element and a printing paste are provided. The printing paste comprises interference particles and is applied by screen printing to a planar backside of the cover element to form a reflective layer for selectively reflecting light.

[0005] Another example of a system with layered structures is found in WO 2014 / 019560 A1. The layered solar cell described therein comprises a top-side transparent protective layer, layers of a photovoltaic layer sequence, and a first and second thermal layer. The aforementioned layers are arranged on a carrier. Light is absorbed in the photovoltaic layers.

[0006] and generates electricity and heat. The resulting heat is converted into electrical energy in the thermal layers. The aforementioned layers are formed, in particular, by a printing process, preferably screen printing. Alternatively or additionally, rotating stencils and / or letterpress and / or gravure printing processes can be used in a roll-to-roll process.

[0007] With the methods used in the state of the art, layered structures that are stably protected against environmental influences can only be produced with great effort.

[0008] Object of the invention

[0009] The object of the invention is to provide a layered structure that can be produced cost-effectively over a large area and with stable protection against environmental influences. It is also an object of the invention to provide a method for producing such a layered structure.

[0010] Description of the invention

[0011] This object is achieved according to the invention by a semi-finished product according to claim 1 and by a method according to claim 20. Advantageous embodiments emerge from the dependent claims.

[0012] In the semi-finished product according to the invention, the layer structure has the following layers:

[0013] - A substrate layer comprising a metal;

[0014] - A functional layer for generating electrical and / or thermal energy, wherein the functional layer is applied over the substrate layer in a construction direction of the layer structure;

[0015] - A first thin film comprising a first material, wherein the first thin film is applied over the functional layer;

[0016] - A second thin film comprising a second material, wherein the second thin film is deposited over the first thin film, wherein a phase boundary is formed between the first thin film and the second thin film.

[0017] The first and second thin films protect the functional layer and the substrate from environmental influences. Therefore, the layered structure according to the invention provides long-term protection against corrosion and weathering. Furthermore, the layered structure according to the invention can be produced over large areas and cost-effectively. Due to the phase boundary, the layered structure provides a particularly strong barrier effect against external influences or substances penetrating the layered structure, in particular, high corrosion protection.

[0018] The build-up direction is, in particular, perpendicular to the substrate layer. The first thin layer is, in particular, applied to the first substrate layer. The second thin layer is, in particular, applied to the first thin layer. The first thin layer has, in particular, a layer thickness of 0.1 micrometers to 200 micrometers, preferably a layer thickness of 0.5 micrometers to 50 micrometers, particularly preferably a layer thickness of 1 micrometer to 40 micrometers, and most particularly preferably a layer thickness of 5 micrometers to 25 micrometers. The second thin layer has, in particular, layer thicknesses in the aforementioned ranges.

[0019] The first material comprises, in particular, polymers, polyester resins, in particular silicone polyester, melamine resins, isocyanates, polyurethane, polyvinylidene fluoride (PVDF), fluoroethyl vinyl ether (FEVE), epoxy, silicone epoxides, polyethers, silicone polyether, polyethylene terephthalate (PET), and / or plastisols. The second material comprises, in particular, one or more of the aforementioned substances. In some embodiments, the first and / or second thin films comprise pigments and / or additives, in particular to filter electromagnetic waves (in particular light). In some embodiments, the thin films are ultraviolet (UV) and / or electron beam (EB) curing. A phase is understood, in particular, to be a spatial region filled with a material in which the material parameters of the material are homogeneous.In particular, the material parameters are homogeneous on a length scale of at least 0.01 micrometers, preferably of at least 0.05 micrometers, particularly preferably of at least 0.1 micrometers. Material parameters include, in particular, optical parameters such as the refractive index of the material, chemical properties of the material and / or order parameters of the material such as its density. A phase interface is understood, in particular, to be an interface between two different phases. A phase interface is understood, in particular, to be an interface at which one phase borders on another phase, wherein in the interface one of the aforementioned material parameters of the material exhibits a discontinuous change during a transition from one phase to the other phase.In particular, the value of the material parameter in one phase is between 70% and 99%, preferably between 80% and 95%, particularly preferably between 85% and 90% of the value of the relevant material parameter in the other phase. Other terms for phase boundary are, in particular, phase boundary and interface. In particular, in some embodiments, the layer structure has two, three, or more phase boundaries, which are preferably formed between layers of the layer structure. Particularly preferably, a phase boundary is formed between the substrate layer and the functional layer and / or a phase boundary is formed between the functional layer and the first thin film.

[0020] In some embodiments of the layer structure, the first and / or the second thin layer comprise in particular a film which is provided in particular with adhesive, preferably with laminating adhesive.

[0021] A functional layer is understood, in particular, to be a layer suitable for generating electromagnetic radiation, in particular light, electricity, and / or heat. A functional layer is understood, in particular, to be a layer comprising electronic components, preferably printed thereon. The functional layer may comprise semiconductors. The functional layer may, in particular, be designed as a storage device for electrical energy and / or as part of a storage device for electrical energy, preferably as part of a battery.

[0022] In some embodiments of the layered structure, films are arranged between two or more layers of the layered structure, in particular between the first thin film, the second thin film, and / or the cover layer. In particular, the thickness of one or more of the films in the layered structure is 20 micrometers to 200 micrometers. In some embodiments, one or more layers of the layered structure are printed, in particular the functional layer. In some embodiments, encapsulating compounds and / or foams, in particular comprising polyisocyanurates (PIR) and / or polyurethanes (PUR), are arranged between two or more layers of the layered structure.

[0023] In a preferred embodiment of the semi-finished product, the substrate layer comprises steel, stainless steel, galvanized steel, and / or a non-ferrous metal, in particular aluminum, wherein the substrate layer is in particular formed as a sheet or rolled foil. Steel is understood, in particular, to mean an iron-carbon alloy with a carbon mass fraction of at most 2 wt%. In some embodiments, the substrate layer comprises a pretreatment layer, in particular a passivation layer, preferably a corrosion protection layer.

[0024] A film is understood in particular to mean a body which is integrated in the layer structure in a solid aggregate state, in particular is applied to other layers of the layer structure and has a maximum thickness of 5 mm, in particular a thickness which lies between the same maximum and minimum values ​​as the thickness of the first thin layer.

[0025] In a particularly advantageous embodiment of the semi-finished product, the first material is different from the second material, wherein, in particular, the first thin layer has a transmittance of at least 85%, in particular at least 90%, preferably at least 95%, and / or the second thin layer has a transmittance of at least 85%, in particular at least 90%, preferably at least 95%. Such transparent thin layers are particularly suitable for protecting functional layers in the field of photovoltaics. The term "transmittance" refers in particular to the permeability of electromagnetic radiation, in particular light and / or UV radiation.The first and second materials comprise, in particular, different polymers, different mechanical properties, crosslinking types, degrees of crosslinking, additives for regulating the transmission of electromagnetic radiation, such as UV absorbers and / or nanoparticulate pigments and / or fillers, different glass transition temperatures, and / or different degrees of absorption of electromagnetic radiation, in particular UV radiation. A degree of crosslinking in a system of macromolecules is understood to mean, in particular, the number of crosslinked sites of the macromolecules, relative to the number of macromolecules, with the macromolecules preferably forming polymers. A type of crosslinking is understood to mean, in particular, the type of chemical bonding of molecules.

[0026] In particular, in some embodiments of the semi-finished product, the degree of crosslinking, the glass transition temperature, and / or the absorption coefficient of the first thin layer is between 75% and 99%, preferably between 80% and 95%, particularly preferably between 85% and 90% of the corresponding degree of crosslinking, the corresponding glass transition temperature, and / or the corresponding absorption coefficient of the second thin layer. In particular, in some embodiments of the semi-finished product, the degree of crosslinking, the glass transition temperature, and / or the absorption coefficient of the second thin layer is between 75% and 99%, preferably between 80% and 95%, particularly preferably between 85% and 90% of the corresponding degree of crosslinking, the corresponding glass transition temperature, and / or the corresponding absorption coefficient of the first thin layer.

[0027] For the purposes of this application, a mixed structure is understood to mean, in particular, a layered structure with multiple layers arranged one above the other, with a phase boundary formed between at least two of the layers. The mixed structure is made, in particular, from various lacquers and / or polymers. The invention features a mixed structure of material layers, with a mixed structure of multilayered material layers having a higher barrier effect against penetrating substances such as moisture, ions, gases, and global radiation than each material considered individually. At the respective phase boundary of the materials, a phase boundary is formed, which creates a barrier effect by changing the material properties. This enables a distribution of the load on the thin films under the influence of heat or radiation energy.

[0028] An advantageous embodiment of the semi-finished product is one in which the first thin layer is formed as a film and / or the second thin layer is formed as a film, wherein the film is particularly formed as an adhesive film and / or a laminated film, wherein the film is preferably designed in multiple layers. A film provides particularly good protection for the semi-finished product.

[0029] A preferred embodiment of the semi-finished product is one in which the first thin layer is formed as an adhesive layer and / or the second thin layer is formed as an adhesive layer. This makes the semi-finished product particularly stable.

[0030] An advantageous embodiment of the semi-finished product is one in which the first thin layer is designed as an electrical conductor, preferably as a Class 1 or Class 2 conductor. This allows the semi-finished product to generate and transport electrical energy particularly effectively. In particular, Class 1 conductors do not undergo any material change through electrical conduction, whereas Class 2 conductors undergo material change through electrical conduction.

[0031] Furthermore, an embodiment of the semi-finished product is preferred in which the second thin layer is designed as an electrical insulator. This provides the semi-finished product with particularly good protection against external electrical influences. In an advantageous embodiment of the semi-finished product, the first thin layer is made of a sol-gel layer and / or the second thin layer is made of a sol-gel layer. This allows the thin layers to be designed simply and with a wide range of functions.

[0032] In a preferred embodiment of the semi-finished product, the functional layer is formed as a photoactive layer. A photoactive layer is understood in particular to be a layer a) whose electrical conductivity increases significantly upon exposure to electromagnetic radiation, in particular light and / or UV radiation; and / or b) which emits electromagnetic radiation, in particular light and / or UV radiation, upon application of an electrical voltage; and / or c) which generates electrical voltage upon exposure to electromagnetic radiation, in particular light and / or UV radiation. The photoactive layer is therefore preferably formed in the form of an LED layer or a PV layer. In particular, the semi-finished product can be used particularly easily in the field of lighting or photovoltaics.

[0033] An embodiment of the semi-finished product is preferred in which the first thin layer is made of lacquer, in particular of clear lacquer and / or the second thin layer is made of lacquer, in particular of clear lacquer.

[0034] For the purposes of this application, a varnish is understood to mean, in particular, a liquid or powdery substance which has:

[0035] Polymers, polyester resins, in particular silicone polyester, melamine resins, isocyanates, polyurethane, polyvinylidene fluoride (PVDF), fluoro ethyl vinyl ether (FEVE), epoxy, silicone epoxides, polyethers, silicone polyethers, polyethylene terephthalate (PET) and / or plastisols, preferably a material suitable for a sol-gel process, particularly preferably silane-crosslinked sol-silicate.

[0036] Furthermore, an embodiment of the semi-finished product is preferred in which a lamination layer is formed between the substrate layer and the functional layer for lamination of the layers applied beneath the lamination layer, wherein the lamination layer comprises, in particular, adhesive and / or a film, in particular a laminated film. The lamination layer provides particularly good protection for the layers formed beneath the lamination layer. Metal and / or polymer films, in particular, can be used for lamination. These films can comprise various layers, and the films can, in particular, be printed.

[0037] An embodiment of the semi-finished product in which the functional layer comprises MXene is advantageous. MXene in particular comprises layers, preferably single atomic layers, with titanium and carbon atoms. MXene is advantageously particularly well-suited for storing electrical energy. In particular, the functional layer can comprise conductive pigments, graphite, graphene, carbon nanotubes, ITO (ATO), and / or metal particles, in particular silver, copper, and / or zinc. To improve the conductivity of these layers, the functional layer can comprise conductor tracks, in particular made of a metal mesh, and / or linearly printed conductor tracks.

[0038] In an advantageous embodiment of the semi-finished product, the semi-finished product comprises the functional layer and at least one further functional layer, wherein the at least one further functional layer is applied over the functional layer, wherein in particular the functional layer and the at least one further functional layer are configured together to generate electrical and / or thermal energy, in particular to generate a thermoelectric current, a thermoelectric voltage and / or as a capacitor. In particular, the functional layer is designed as an electrode and / or the further functional layer is designed as an electrode. In particular, in some embodiments of the semi-finished product, the semi-finished product has three or more functional layers.Preferably, in some embodiments of the semi-finished product, one functional layer can be configured as an electrode (in particular as a front electrode), another functional layer can be configured as a buffer layer, another functional layer can have components and / or a layer for storing electrical energy or conducting electrical current, and / or another functional layer can be configured as another electrode (in particular as a back electrode). The aforementioned functional layers are preferably arranged one above the other in the construction direction.

[0039] The generation of electrical and / or thermal energy by the functional layers occurs in particular via the Seebeck effect or the Peltier effect. The functional layers can be designed as a double-layer capacitor, in particular as an electrochemical capacitor (supercapacitor). Advantageously, in such an embodiment, the semi-finished product can provide particularly high electrical and / or thermal energy. The functional layer and the further functional layer can be designed in particular as a storage device for electrical energy and / or as part of a storage device for electrical energy, preferably as a battery.

[0040] An advantageous embodiment of the semi-finished product is one in which an adhesion promoter layer is applied between the substrate layer and the functional layer, with a corrosion protection layer being applied between the adhesion promoter layer and the functional layer. This makes the semi-finished product particularly stable.

[0041] A preferred embodiment of the semi-finished product is one with a cover layer comprising silicon and / or silicon oxide, wherein the cover layer is applied over the second thin layer. The cover layer provides particularly good protection for the semi-finished product.

[0042] Silicon oxides are understood to mean, in particular, silicon monoxide and silicon dioxide. In particular, the cover layer has a mass fraction of silicon dioxide of 90 wt% to 95 wt%. The cover layer is in particular formed as a thin film, preferably with a thickness in the aforementioned ranges of the thickness of the first thin film. The cover layer is preferably formed with a transmittance of at least 85%, in particular at least 90%, preferably at least 95%. In some embodiments, the cover layer has nanoparticles, in particular with a diameter of 50 nm to 500 nm. This can serve, for example, to improve the self-cleaning and / or scratch resistance of the cover layer and / or to filter incident light.

[0043] In a further development of the aforementioned embodiment of the semi-finished product, the cover layer is made of a sol-gel layer. A sol-gel layer is understood in particular to be a layer produced using a sol-gel process. In particular, silicon, aluminum, zirconium, titanium and / or an alkoxide, preferably an alkoxide of a metal, particularly preferably a silicon precursor, very particularly preferably tetramethyl orthosilicate, tetraethyl orthosilicate and / or tetraisopropyl orthosilicate, can be used as the material for producing a sol-gel layer in a sol-gel process. In particular, the first thin film, the second thin film and / or the cover layer can comprise one or more of the aforementioned materials. Sol-gel layers are characterized by high mechanical stability. The sol-gel layer is in particular inorganic and / or hybrid polymer. The cover layer is preferably in the form of a sol-gel layer.

[0044] An advantageous embodiment of the semi-finished product is one in which an additional top layer is applied between the corrosion protection layer and the functional layer. The primer of the adhesion promoter layer and the additional top layer improve the mechanical stability of the layer structure.

[0045] A preferred embodiment of the semi-finished product is one in which a carrier layer comprising a foam and / or a composite material is applied beneath the substrate layer. This provides additional mechanical stabilization of the semi-finished product, in particular the substrate. A composite material is understood to mean, in particular, a composite material.

[0046] An advantageous embodiment of the semi-finished product is one in which a further layer is applied beneath the substrate layer, which layer is identical to one of the aforementioned layers of the layer structure, wherein, in particular, layers beneath the substrate layer are applied in the reverse order to layers above the substrate layer in the construction direction. This allows the thermal and / or electrical energy provided by the semi-finished product and the protection of the semi-finished product to be efficiently increased.

[0047] In some embodiments, the aforementioned layers are applied in strip form and / or in the form of spaced-apart sections of the respective layer.

[0048] The semi-finished product can, in particular, have a layered structure with a thin layer in the form of a film and a thin layer made from a clear varnish. The semi-finished product can, in particular, have a layered structure with a thin layer in the form of a film and a thin layer made from a material suitable for a sol-gel process. The semi-finished product can, in particular, have a layered structure with thin layers, each made from a material suitable for a sol-gel process, wherein the materials for the respective thin layer preferably differ. The semi-finished product can, in particular, have a layered structure with thin layers, each made from a clear varnish, wherein the clear varnishes for the respective thin layer preferably differ.The semi-finished product can in particular have a layer structure with a thin layer made of a clear varnish and a thin layer made of a material suitable for a sol-gel process.

[0049] The semi-finished product can in particular have a layer structure with a thin layer comprising a film, a thin layer made from a clear varnish and a thin layer made from a further clear varnish. The semi-finished product can in particular have a layer structure with a thin layer comprising a film, a thin layer made from a clear varnish and a thin layer made from a material suitable for a sol-gel process. The semi-finished product can in particular have a layer structure with a thin layer comprising a film, a thin layer made from a material suitable for a sol-gel process and a thin layer made from a further material suitable for a sol-gel process.The semi-finished product can, in particular, have a layered structure with a thin layer made of a clear varnish, a thin layer made of another clear varnish, and a thin layer made of a material suitable for a sol-gel process. The semi-finished product can, in particular, have a layered structure with a thin layer made of a clear varnish, a thin layer made of a material suitable for a sol-gel process, and a thin layer made of another material suitable for a sol-gel process.

[0050] The layer structure of the semi-finished product can in particular have:

[0051] - A substrate layer, in particular comprising a stainless steel;

[0052] - A functional layer;

[0053] - A further, particularly conductive, functional layer;

[0054] - A first thin layer;

[0055] - And / or a second thin film.

[0056] The aforementioned layers of the layered structure are arranged one above the other, particularly in the direction of construction. The substrate layer can be used, in particular, as an anode. The additional functional layer can be used, in particular, as a front electrode.

[0057] The layer structure of the semi-finished product can in particular have:

[0058] - A substrate layer, in particular comprising a galvanized steel;

[0059] - A layer of primer;

[0060] - A primer layer made from a base coat;

[0061] - A conductive functional layer, used in particular as an anode;

[0062] - Another functional layer;

[0063] - Another functional layer, which is used in particular as a front electrode;

[0064] - A first thin layer, which is made in particular from a clear varnish; - A second thin layer, which is in particular designed as a film and / or made from another clear varnish;

[0065] - And / or a third thin layer, which is made in particular of a lacquer and / or a material suitable for a sol-gel process.

[0066] The aforementioned layers of the layer structure are arranged one above the other, in particular in the construction direction.

[0067] In some embodiments, the semi-finished product has the following properties in particular:

[0068] A nominal layer thickness (in particular according to test standard EN 13523-1) in the range of 45 micrometers to 55 micrometers, a gloss of semi-matt 20 to 25 gloss units at a 60° angle, a smooth or textured surface, a RUV class (in particular according to test standards DIN EN 10169, EN 13523-10, EN 13523-14) of RUV 4, a corrosion resistance (in particular according to test standard EN 10169) of RC4, a protection duration and corrosivity category (in particular according to test standards DIN 55634, DIN EN ISO 12944-2) of C4H to C5M, a creepage at the scribe (in particular according to test standard EN 13523-8) of less than 2 mm after 500 hours, no blistering on the surface (in particular according to test standard EN 13523-8) after 500 hours, a corrosion resistance (in particular according to the test standard EN 13523-26) in a constant climate of class 2 after 1000 hours, a fire behaviour (in particular according to the test standard DIN 4102) of class A2,an Erichsen cupping adhesion (in particular according to test standard EN 13523-6) that does not show any detachment at 4 mm, an adhesion after bending (in particular according to test standard EN 13523-7) greater than or equal to 1 T, a scratch hardness (in particular according to test standard EN 13523-12) greater than 800 g, a Buchholz hardness (in particular according to test standard EN ISO 2815) greater than 60, a cross-cut hardness (in particular according to test standard ISO 2409) of Gt 0, a temperature resistance between -30°C and +80°C.

[0069] A method according to the invention for producing a semi-finished product with a layer structure comprises the following steps: a) applying a functional layer in a build-up direction over a substrate layer, wherein the substrate layer comprises a metal; b) applying a first thin layer over the functional layer, wherein the first thin layer comprises a first material; c) applying a second thin layer over the first thin layer, wherein the second thin layer comprises a second material, wherein a phase boundary is formed between the first thin layer and the second thin layer during the application of the second thin layer.

[0070] A preferred embodiment of the method is one in which the first thin layer and the second thin layer are applied using a coil coating process. Applying the first and second thin layers using the coil coating process results in a uniform and easily controllable formation of these layers. The functional layer and the substrate layer can be protected from corrosion, weathering, and other environmental influences over a large area and cost-effectively, particularly by sealing.

[0071] The temperature during the coil coating process is in particular between 80°C and 400°C, preferably between 80°C and 280°C. In some embodiments of the process, EB or UV drying systems can be used. The drying time is in particular between 3 seconds and 60 minutes, especially between 5 seconds and 40 seconds.

[0072] A preferred embodiment of the method is one in which a layer of the layer structure is applied over an underlying layer of the layer structure only if the liquid content of the underlying layer is less than or equal to a minimum value. The minimum value of the liquid content is in particular a mass fraction of 1 wt.%, preferably 0.1 wt.%, particularly preferably 0.01 wt.%, very particularly preferably 0.001 wt.% of the underlying layer at the time at which the layer is applied over the underlying layer. In an advantageous embodiment of the method, the functional layer is applied using a coil coating process. This allows the functional layer to be applied in a well-controllable and cost-effective manner.

[0073] Alternatively, a preferred embodiment of the method involves applying the functional layer using a screen printing process. This enables particularly precise printing of the functional layer.

[0074] The aforementioned process variants "coil coating" and "screen printing" each represent independent aspects of the invention. Both process variants can be combined independently with all other process steps and features described here.

[0075] In general, a coil-coating job can include digital printing. Digital printing can be performed with one or more print heads. If multiple print heads are used, they are preferably arranged in parallel.

[0076] An embodiment of the method in which the first thin film is produced from a lacquer, in particular a clear lacquer, and / or the second thin film is produced from a lacquer, in particular a clear lacquer, is advantageous. The lacquer for producing the first thin film comprises in particular: polymers, polyester resins, in particular silicone polyesters, melamine resins, isocyanates, polyurethane, polyvinylidene fluoride (PVDF), fluoro ethyl vinyl ether (FEVE), epoxy, silicone epoxides, polyethers, silicone polyethers, polyethylene terephthalate (PET) and / or plastisols, preferably a material suitable for a sol-gel process, particularly preferably silane-crosslinked sol-silicate. The lacquer for producing the second thin film comprises in particular one of the aforementioned substances.

[0077] A further preferred embodiment of the method is one in which two layers of the layered structure are applied together in a coil coating process, in particular the first thin layer and the second thin layer. This makes the method time-saving. In some embodiments, in particular, three layers of the layered structure are applied together. An advantageous embodiment of the method is one in which a cover layer is applied over the second thin layer, in particular in a coil coating process. The cover layer provides particularly good protection for the layered structure.

[0078] In a further development of the aforementioned process, the cover layer is produced from a sol-gel layer. The material composition of the sol-gel layer, which is produced using a sol-gel process, can be precisely controlled. In particular, the cover layer is identical to the sol-gel layer.

[0079] The semi-finished products according to the invention can be further processed into components, in particular facade elements. The semi-finished products can be formed completely or partially, in particular by bending, roll forming, and / or deep drawing. Sandwich elements, in particular, can be produced from the semi-finished products.

[0080] Further advantages of the invention will become apparent from the description and the drawings. Likewise, the above-mentioned and further-described features can be used individually or in combination in any desired manner. The embodiments shown and described are not intended to be exhaustive, but rather serve as examples for describing the invention.

[0081] Detailed description of the invention and drawing

[0082] Fig. 1 shows a schematic section through a semi-finished product.

[0083] Fig. 1 shows a section through a semi-finished product 10 with a layered structure 12. The layered structure 12 has a substrate layer 14 which is formed from at least one metal, wherein a zinc layer 16 for protection against corrosion is applied to the substrate layer 14 in a construction direction AR of the layered structure 12. A corrosion inhibitor layer 18 is applied to the zinc layer 16, in particular as part of a pretreatment, preferably for protection against oxygen corrosion. A primer layer 20 is located on the corrosion inhibitor layer 18 in order to improve the adhesion of the layers adjacent to the primer layer 20. A primer layer 22 extends over the primer layer 20 and is produced in particular with a base coat. The primer layer 22 serves, among other things, to provide protection and to level out unevenness on the underlying layers.A lamination layer 24 is arranged on the primer layer 22, which in particular protects the underlying layers. A film 26 is located on the lamination layer 24, which also serves as a lamination. A further primer layer 28 is applied to the film 26. A functional layer 30 for generating light, heat, and / or electricity extends over the primer layer 28 and is printed, in particular, with electronic components (not shown).

[0084] A further lamination layer 24 is arranged on the functional layer 30. A further film 26, which also serves for lamination, is located on the lamination layer 24. A first thin film 32, comprising a first material 34, extends on the further film 26. A second thin film 36 comprising a second material 38 is arranged on the first thin film 32, wherein the second thin film 36 differs in particular from the first thin film 32, preferably with regard to mechanical properties, the absorption of electromagnetic radiation and / or the glass transition temperature. A phase boundary surface 46 is formed between the first thin film 32 and the second thin film 36. A cover layer 40, which comprises silicon and / or silicon oxides, is applied to the second thin film 36.

[0085] Arranged beneath the substrate layer 14 is a further zinc layer 16, beneath which is located a further corrosion protection layer 18. A further adhesion promoter layer 20 is formed beneath the further adhesion promoter layer 20. A further primer layer 28 extends beneath this further adhesion promoter layer 20. This is followed downwardly by a further lamination layer 24, beneath which extends an adhesive layer 42. A carrier layer 44 is formed beneath the adhesive layer 42, which supports the aforementioned layers of the layer structure 12. Referring to the figure of the drawing, the invention relates in particular to a semi-finished product 10, wherein the semi-finished product 10 has the following layers:

[0086] - A substrate layer 14 containing at least one metal;

[0087] - A functional layer 30 which is designed to generate light, current and / or heat, wherein the functional layer 30 is arranged above the substrate layer 14 in a construction direction AR which is perpendicular to the substrate layer 14;

[0088] - A first thin film 32 containing at least a first material 34, wherein the first thin film 32 is arranged above the functional layer 30;

[0089] - A second thin film 32 containing at least one second material 38, wherein the second thin film 38 is arranged above the first thin film 32, wherein a phase boundary surface 46 is formed between the first thin film 32 and the second thin film 38.

[0090] List of reference symbols

[0091] 10 semi-finished product is 32 first thin film

[0092] 12 Layer structure 34 First material 14 Substrate layer 36 Second thin film

[0093] 16 zinc layer 38 second material

[0094] 18 Corrosion protection agent 40 Top layer 20 42 Adhesive layer

[0095] 20 Adhesion promoter layer 44 Carrier layer 22 Primer layer 46 Phase interface

[0096] 24 Laminating layer

[0097] 26 Slide

[0098] 28 Primer layer 25 AR Build direction

[0099] 30 functional layer

Claims

AMENDED CLAIMS received by the International Bureau on 24 November 2025 (24.11.2025) 1. Semi-finished product (10) with a layered structure (12), wherein the layered structure (12) has: - A substrate layer (14) comprising a metal; - A functional layer (30) for generating electrical and / or thermal energy, wherein the functional layer (30) is applied in a build direction (AR) of the layer structure (12) over the substrate layer (14); - A first thin film (32) comprising a first material (34), wherein the first thin film (32) is applied over the functional layer (30); - Having a second thin film (36) comprising a second material (38), wherein the second thin film (38) is applied over the first thin film (32), wherein a phase interface (46) is formed between the first thin film (32) and the second thin film (36).

2. Semi-finished product according to claim 1, wherein the substrate layer (14) comprises steel, stainless steel, galvanized steel and / or a non-ferrous metal, in particular aluminium, wherein the substrate layer (14) is in particular formed as sheet metal or rolled foil.

3. Semi-finished product according to one of the preceding claims, wherein the first material (34) is different from the second material (38), wherein in particular the first thin film (32) has a transmittance of at least 85%, in particular at least 90%, preferably at least 95% and / or the second thin film (32) has a transmittance of at least 85%, in particular at least 90%, preferably at least 95%. 26 AMENDED SHEET (ARTICLE 19) 4. Semi-finished product according to one of the preceding claims, wherein the first thin layer (32) is formed as a film (26) and / or the second thin layer (36) is formed as a film (26), wherein in particular the film (26) is formed as an adhesive film and / or laminated film, wherein the film (26) is preferably designed as a multi-layered film.

5. Semi-finished product according to one of the preceding claims, wherein the first thin layer (32) is formed as an adhesive layer (42) and / or the second thin layer (36) is formed as an adhesive layer (42).

6. Semi-finished product according to one of the preceding claims, wherein the first thin film (32) is designed as an electrical conductor, preferably as a first-class or second-class electrical conductor.

7. Semi-finished product according to one of the preceding claims, wherein the second thin film (36) is designed as an electrical insulator.

8. Semi-finished product according to one of the preceding claims, wherein the first thin film (32) is made from a sol-gel layer and / or the second thin film (36) is made from a sol-gel layer.

9. Semi-finished product according to one of the preceding claims, wherein the functional layer (30) is designed as a photoactive layer.

10. Semi-finished product according to one of the preceding claims, wherein the first thin layer (32) is made of lacquer, in particular clear lacquer and / or the second thin layer (36) is made of lacquer, in particular clear lacquer.

11. Semi-finished product according to one of the preceding claims, wherein a laminating layer (24) for laminating the material applied under the laminating layer (24) is located between the substrate layer (14) and the functional layer (30). 27 AMENDED SHEET (ARTICLE 19) layers are formed, wherein the laminating layer (24) in particular comprises adhesive and / or a film, in particular a laminated film.

12. Semi-finished product according to one of the preceding claims, wherein the functional layer (30) comprises MXene.

13. Semi-finished product according to one of the preceding claims, wherein the semi-finished product (10) comprises the functional layer (30) and at least one further functional layer (30), wherein the at least one further functional layer (30) is applied over the functional layer (30), wherein in particular the functional layer (30) and the at least one further functional layer (30) are together configured to generate electrical and / or thermal energy, in particular to generate a thermoelectric current, a thermoelectric voltage and / or as a capacitor.

14. Semi-finished product according to one of the preceding claims, wherein an adhesion promoter layer (20) is applied between the substrate layer (14) and the functional layer (30), wherein in particular a corrosion protection layer (18) is applied between the adhesion promoter layer (20) and the functional layer (30).

15. Semi-finished product according to one of the preceding claims comprising a cover layer (40) comprising silicon and / or silicon oxide, wherein the cover layer (40) is applied over the second thin film (36).

16. Semi-finished product according to claim 15, wherein the cover layer (40) is made from a sol-gel layer.

17. Semi-finished product according to claim 14 and one of claims 15 to 16, wherein a further top layer (40) is applied between the corrosion protection layer (18) and the functional layer (30). 28 AMENDED SHEET (ARTICLE 19) 18. Semi-finished product according to one of the preceding claims, wherein a support layer (44) having a foam and / or a composite material is applied below the substrate layer (14).

19. Semi-finished product according to one of the preceding claims, wherein a further layer according to one of claims 1 to 17 is applied below the substrate layer (14), wherein in particular layers below the substrate layer (14) are applied in the build-up direction (AR.) in reverse order to layers above the substrate layer (14).

20. A method for producing a semi-finished product (10) according to one of the preceding claims, comprising the steps of: a) applying a functional layer (30) in a build-up direction (AR) over a substrate layer (14), wherein the substrate layer (14) comprises a metal; b) applying a first thin film (32) over the functional layer (30), wherein the first thin film (32) comprises a first material (34); c) applying a second thin film (36) over the first thin film (32), wherein the second thin film (36) comprises a second material (38), wherein a phase interface (46) is formed between the first thin film (32) and the second thin film (36) during the application of the second thin film (36).

21. as described in claim 20, wherein the application of the first thin film (32) and the second thin film (36) is carried out in a coil coating process.

22. Method according to one of claims 20 or 21, wherein the application of a layer of the layer structure over an underlying layer of the layer structure only takes place if the liquid content of the underlying layer is less than or equal to a minimum value. 29 AMENDED SHEET (ARTICLE 19) 23. experienced according to one of claims 20 to 22, wherein the application of the functional layer (30) is carried out in a coil coating process.

24. Method according to one of claims 20 to 22, wherein the application of the functional layer (30) is carried out in a screen printing process.

25. Method according to one of claims 20 to 24, wherein the first thin layer (32) is produced from a varnish, in particular a clear varnish and / or the second thin layer (36) is produced from a varnish, in particular a clear varnish.

26. Method according to one of claims 20 to 25, wherein two layers of the layer structure (12) are applied together in a coil coating process, in particular the first thin film (32) and the second thin film (36).

27. Method according to any one of claims 20 to 26, wherein a top layer (40) is applied over the second thin layer (36), in particular in a coil coating process.

28. Method according to claim 27, wherein the cover layer (40) is produced from a sol-gel layer. 30 AMENDED SHEET (ARTICLE 19)

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