Method for producing a composite pane

Abstract

The invention relates to a method for producing a composite pane (100), having the following steps: a) providing a stack containing a first pane (1) with a first surface (I) and a second surface (II) and a second pane (3) with a third surface (III) and a fourth surface (IV), said first pane (1) and second pane (3) being rigidly connected to one another by an intermediate layer (12), said intermediate layer (12) having a frame-shaped seal (5) with a recess (8), a non-cured, optically clear liquid adhesive (7) being provided in the recess (8), said optically clear adhesive (7) being curable by means of electromagnetic radiation, a first masking layer (13) which is made of an opaque material (16) being provided on the first pane (1) or on the second pane (3) or between the first pane (1) and the second pane (3), said masking layer having a non-perforated masking layer region (15) and a perforated masking layer region (14), the opaque material (16) having a plurality of perforations (25) in the perforated masking layer region (14), the optically clear adhesive (7) being divided into a first adhesive region (18) and a second adhesive region (19) with respect to the stacking direction, the first adhesive region (18) being covered by the perforated masking layer region (14) and the second adhesive region (19) not being covered by the first masking layer (13), and b) irradiating the stack with electromagnetic radiation (24) in order to cure the optically clear adhesive (7), the first adhesive region (18) and the second adhesive region (19) of the optically clear adhesive (7) being irradiated with the electromagnetic radiation (24), the first adhesive region (18) being irradiated with the electromagnetic radiation (24) through the perforated masking layer region (14).

Description

[0001] Method for manufacturing a composite disc

[0002] The invention lies in the technical field of industrial disc manufacturing and relates to a method for manufacturing a composite disc, in particular a composite disc manufactured by the method and its use.

[0003] Laminated glass panes typically consist of two panes and an interlayer that bonds (laminates) them together. This interlayer is typically made of one or more thermoplastic bonding layers, especially PVB layers. Laminated glass panes are generally manufactured by autoclaving, a process in which the panes are bonded together at high temperature and pressure by the thermoplastic bonding layers.

[0004] It is known to provide a laminated glass panel with an electrical insert embedded in the interlayer. Electrical inserts are, for example, designed as electro-optical functional elements. These are planar structures with electrically controllable optical properties of an active layer. That is, the optical properties of the active layer, and in particular its transparency and scattering behavior, can be controlled by an electrical voltage. Examples of electro-optical functional elements are SPD functional films (SPD = Suspended Particle Device), which are known, for example, from EP 0876608 B1 and WO 2011033313 A1, as well as PDLC functional films (PDLC = Polymer Dispersed Liquid Crystal), which are known, for example, from DE 102008026339 A1.

[0005] Electro-optical functional elements are commercially available as multilayer films, with the active layer embedded between two surface electrodes that serve to apply a voltage to control the active layer. As a rule, the two surface electrodes are arranged between two carrier films, typically made of PET. In the production of the laminated glass, the electro-optical functional film is cut to the desired size and shape and inserted between the thermoplastic bonding layers, by means of which the glass is laminated to form the composite glass. A typical application is windshields with electrically adjustable sun visors, which are known, for example, from DE 102013001334 A1, DE 102005049081 B3, DE 102005007427 A1 and DE 102007027296 A1.To compensate for the thickness difference between the areas with and without the electrical insert, it is known to use a frame-shaped layer of a thermoplastic material, which is inserted between the two thermoplastic bonding layers and surrounds the electrical insert along its perimeter. Thus, the electrical insert is placed in a recess of the frame-shaped layer, which surrounds the electrical insert like a passe-partout to protect it from excessive mechanical stress during the lamination of the laminated glass. For example, WO 2007 / 122428 A1 describes the use of two PVB bonding layers with a thickness of 0.76 mm and a PVB frame-shaped layer with a thickness of 0.38 mm to integrate an SPD functional film into a laminated glass. WO 2007 / 122429 A1 describes the same structure for liquid crystal-based functional films.

[0006] Although the use of a frame-shaped layer can significantly reduce the mechanical stress on the electrical insert, laminating the composite disc still places considerable mechanical stress on the electrical insert, especially when laminating curved discs, which is often the case. The two discs may also have different curvatures due to tolerances or because this is desired. This can lead to reversible as well as irreversible defects in the electrical insert, such as a damaged active layer in an electro-optical functional film. Certain electrical inserts can also be particularly sensitive to mechanical stress, such as photovoltaic modules integrated into the composite disc, which can even break during lamination.The use of optically clear adhesives for firmly bonding the two panes of a laminated glass unit is well-known, as the optically clear adhesive eliminates the need for lamination. A particularly fast and efficient method for curing the optically clear adhesive is irradiation with ultraviolet light (UV radiation), which is especially suitable for laminated glass units due to their transparency.

[0007] Furthermore, it is common practice in vehicle manufacturing to use laminated glass with a black print. This black print is typically located around the perimeter of the laminated glass, bordering its transparent area. The primary purpose of this black print is to protect the adhesive used to bond the laminated glass to the vehicle body from UV radiation. If an optically clear adhesive is used, it may be partially obscured by the black print, which negatively impacts UV curing, as the black print is designed to largely block UV radiation. Consequently, the optically clear adhesive may not cure completely, or complete curing may take a very long time and require significant energy.Furthermore, the area of ​​the optically clear adhesive directly visible to UV radiation cures significantly faster than the area of ​​the optically clear adhesive concealed by the black print. This uneven curing of the optically clear adhesive can lead to mechanical stresses in the laminated glass. Such mechanical stresses can, in turn, adversely affect the mechanical load-bearing capacity of integrated electrical inserts.

[0008] WO 2023 / 247762 A1 discloses a glazing in the manufacture of which an optically clear adhesive is irradiated through a perforated masking layer to cure it.

[0009] In contrast, the object of the present invention is to provide an improved method for manufacturing composite lenses. In particular, the method is intended to improve the production of composite lenses with integrated electrical inserts, thereby significantly reducing or even completely eliminating mechanical stress on these inserts. The method is intended to enable, in particular, time- and cost-efficient production of the composite lenses. Furthermore, the method should be feasible with production equipment commonly used in the industrial mass production of composite lenses, in order to produce composite lenses with high optical quality and low reject rates in large quantities simply, cost-effectively, and reliably.

[0010] These and other problems are solved according to the invention by a method for manufacturing a composite disc as described in the independent claim. Advantageous embodiments of the invention are described in the dependent claims. A composite disc manufactured in particular by the method according to the invention and its use are described in the contingent claims.

[0011] According to the invention, a method for manufacturing a composite disc is shown, which comprises the following steps:

[0012] Step a)

[0013] First, a stack is provided, comprising a first disk and a second disk, the first and second disks being firmly connected to each other by an intermediate layer. Each disk has two surfaces (main surfaces) intended for transparency, which are arranged substantially parallel to each other, as well as an intermediate edge surface. The first disk has a first surface I and a second surface II. The second disk has a third surface III and a fourth surface IV.

[0014] The intermediate layer comprises a frame-shaped seal (e.g., a frame-shaped layer) with a recess, wherein an uncured, optically clear adhesive in liquid form is arranged in the recess of the frame-shaped seal. The uncured, optically clear adhesive consists of a material that can be cured by means of electromagnetic radiation, preferably radiation in the ultraviolet wavelength range or UV radiation.

[0015] Furthermore, a first masking layer made of an opaque material is arranged on the first disk or the second disk or between the first disk and the second disk.

[0016] The first masking layer has a perforated masking area in which the opaque material of the first masking layer is provided with numerous perforations (holes or openings). The perforated masking area partially covers the uncured, optically clear adhesive. Thus, the uncured, optically clear adhesive can be divided into a first adhesive area and a second adhesive area, whereby, relative to the stacking direction of the stack, the first adhesive area is (completely) covered by the perforated masking area, and the second adhesive area is not covered by the first masking layer (and therefore also not by the perforated masking area).

[0017] Here and in the following, the masking layer, which contains a perforated masking layer area, is referred to as the "first" masking layer in order to distinguish it from an optionally present second masking layer.

[0018] The first masking layer, made of an opaque material, is preferably arranged on the second surface (II) of the first disk, or on the third surface (III) or fourth surface (VI) of the second disk, or between the frame-shaped seal and the first disk, or between the frame-shaped seal and the second disk. The first masking layer, made of an opaque material, is particularly preferably arranged on the second surface (II) of the first disk or the third surface (III) of the second disk. Step b)

[0019] Irradiation of the stack provided in step a) with electromagnetic radiation, preferably UV radiation, to cure the uncured, optically clear adhesive, wherein the first adhesive area and the second adhesive area of ​​the uncured, optically clear adhesive are irradiated with the electromagnetic radiation, the first adhesive area being irradiated with the electromagnetic radiation through the perforated masking area of ​​the first masking layer. This cures the uncured, optically clear adhesive and firmly bonds the two discs together. The composite disc is thereby produced.

[0020] The method according to the invention can be used very advantageously in composite windows with an integrated electrical insert, although the method is not limited to this. Rather, it can also be used advantageously and beneficially in composite windows without an integrated electrical insert.

[0021] In the inventive method, a particularly advantageous feature is that the first adhesive area covered by the first masking layer can be irradiated with electromagnetic radiation through the perforated area of ​​the masking layer. This allows the uncured, optically clear adhesive to be fully cured in the covered area in a time- and cost-efficient manner. Uneven curing of different areas of the uncured, optically clear adhesive and the resulting generation of mechanical stresses in the composite disc can be advantageously avoided. These are significant advantages of the inventive method.

[0022] For the purposes of this invention, the term "overlap" refers to the stacking direction of the stack, which corresponds to a perpendicular view (i.e., in the stacking direction) through the composite disk. The different layers can also be viewed in orthogonal projection onto one of the disk surfaces to determine whether overlap exists.

[0023] The first masking layer, as well as any optional second masking layer, consists of an opaque material and is preferably printed onto the surface of the disc using a printing process, particularly screen printing. In accordance with common practice in industrial mass production, for example, a masking print can be made of enamel, whereby an electrically non-conductive material, typically a black-tinted (e.g., ceramic) screen printing ink, is printed and fired onto it, preferably using screen printing. Advantageously, the masking layer(s) can be produced using conventional methods and materials.

[0024] If a second masking layer is provided and the first masking layer is arranged on a disk or between a disk and the frame-shaped seal, the second masking layer is arranged on the other disk or between the other disk and the frame-shaped seal. If a second masking layer is provided and the first masking layer is arranged on a disk, the second masking layer is preferably arranged on the other disk.

[0025] The first masking layer has a perforated area, which is referred to in the present description of the invention as the "perforated masking layer area". The first masking layer also has a non-perforated masking layer area, which, unlike the perforated masking layer area, is not provided with perforations. The first masking layer comprises the non-perforated masking layer area and the perforated masking layer area. The perforated masking layer area is arranged directly adjacent to the non-perforated masking layer area.

[0026] The composite pane has an edge (end-face surface) that borders the composite pane. The non-perforated masking layer area is located between the edge of the pane and the perforated masking layer area. Therefore, the perforated masking layer area is located on the inside of the non-perforated masking layer area, with the term "inside" referring to the surface of the composite pane.

[0027] It is essential that the non-perforated masking layer area of ​​the first masking layer is not arranged in overlap with the optically clear adhesive. The non-perforated masking layer area is arranged at least partially in overlap with the frame-shaped seal of the intermediate layer, preferably extending in overlap or perpendicular view through the composite disc to the recess of the frame-shaped seal without covering the optically clear adhesive arranged in the recess. Preferably, the non-perforated masking layer area completely covers the frame-shaped seal without covering the optically clear adhesive. The first masking layer thus has a non-perforated masking layer area and a perforated masking layer area.The non-perforated masking layer advantageously conceals the frame-shaped seal of the intermediate layer and, if applicable, other components of the laminated glass, thus significantly improving the aesthetic appearance of the laminated glass. Furthermore, it provides good protection for the underlying structures against UV radiation from the sun, such as an adhesive bead used to bond the laminated glass to a vehicle frame. Conversely, the perforated masking layer allows the optically clear adhesive to be cured using electromagnetic radiation.

[0028] The non-perforated masking layer area is opaque, which, in accordance with the present invention, corresponds to a light transmission of less than 5% and, in particular, less than 1% or even 0%. The light transmission of windows can be determined according to ECE Regulation No. 43. In this method, a light source (e.g., standard light source A) is placed on one side of the window and a radiation detector on the other side, with the ratio of the transmitted light to the incident light yielding the light transmission in %.

[0029] The perforated masking layer area of ​​the first masking layer has numerous perforations (i.e., holes or openings in the first masking layer). These perforations are areas of the first masking layer where no opaque material is present, thus ensuring that the electromagnetic radiation required to cure the optically clear adhesive is not blocked by the opaque material. Each perforation is surrounded by the opaque material of the first masking layer. In the interior of the perforated masking layer area, the perforations are completely surrounded by the opaque material. In the periphery of the perforated masking layer area of ​​the first masking layer, the perforations may only be partially surrounded by the opaque material.Thus, the perforations are individualizable areas separated from each other by opaque material, with each perforation being completely separated from any other perforation by opaque material; that is, the perforations are not continuous. Rather, the opaque material is continuous. Due to the perforations, the perforated masking layer area of ​​the first masking layer is not solid. The perforated masking layer area of ​​the first masking layer therefore differs fundamentally from conventional masking prints, which can be semi-transparent, usually in sections, for example, in the form of a dot matrix, stripe matrix, or grid. A known method is the creation of a masking print that exhibits a gradient, for example, from a solid opaque coverage to a semi-transparent coverage.A grid-like area of ​​a conventional masking print has numerous printed areas of opaque material, each bordered by a continuous area containing no opaque material. The perforated masking layer area of ​​the first masking layer is therefore different from a grid-like printed area of ​​a masking print. Because of the perforations, the perforated masking layer area is not opaque and can also be described as "semi-transparent".

[0030] The intermediate layer of the stack contains (before step b) an uncured, optically clear liquid adhesive. Liquid optically clear adhesives (LOCA) are well known to those skilled in the art and are readily available commercially from a wide variety of suppliers. After step b), the intermediate layer of the stack contains a cured, optically clear adhesive.

[0031] Optically clear adhesives are generally characterized by high optical quality with high light transmission and low distortion. They are primarily used where a virtually invisible adhesive layer is required, for example, in displays or touch panels. Optically clear adhesives are frequently used in touch-sensitive displays, for instance, to bond them to an LCD screen or to join plastic covers to touch-sensitive displays.

[0032] In the inventive method, an uncured, optically clear liquid adhesive is used, which, after curing, firmly bonds the two panes of the composite disc together. The uncured, optically clear liquid adhesive can, in principle, be of any type, as long as it is sufficiently fluid to be poured into the recess of the frame-shaped seal and curing in the stack by electromagnetic radiation, in particular UV radiation, is possible. The optically clear adhesive can, for example, contain or consist of polyurethane (PU), polyacrylate, polyacetate resin, casting resin, or a copolymer or mixture thereof. Advantageously, the optically clear adhesive consists of a casting resin, in particular based on polyurethane or silicone. The optically clear adhesive is, for example, a one-component or two-component adhesive. The uncured, optically clear adhesive is curable, i.e.,It can be irreversibly cured into a solid state. Typically, it is a plastic that is brought into a polymer-crosslinked state through curing. This distinguishes the optically clear adhesive significantly from a thermoplastic material (e.g., PVB), which, although also optically transparent, can always be softened again (i.e., reversibly) by applying heat, and in particular, can be brought back into a flowable state. In contrast, the optically clear adhesive cannot be brought back into a flowable state once it has cured. Therefore, the optically clear adhesive is not a thermoplastic.

[0033] In the method according to the invention, the uncured, optically clear adhesive is cured by electromagnetic radiation, in particular UV radiation, IR radiation, or microwave radiation, preferably UV radiation. The curing time of the uncured, optically clear adhesive can be influenced by temperature in many curing processes. In particular, curing can be accelerated by the application of heat. Conversely, curing can be slowed down by cooling. The curing time can therefore be controlled, for example, by heating or cooling the uncured, optically clear adhesive. The material of the uncured, optically clear adhesive is selected such that curing by electromagnetic radiation, in particular UV radiation, IR radiation, or microwave radiation, preferably UV radiation, is possible.

[0034] The uncured, optically clear adhesive can be irradiated with electromagnetic radiation through the perforations of the perforated masking layer in the first adhesive area to induce curing. In principle, the size, shape, arrangement, and density of the perforations can be chosen arbitrarily, as long as it is ensured that the uncured, optically clear adhesive can be cured through the perforations by means of electromagnetic radiation.

[0035] The larger the total area of ​​the perforations, the more radiation can pass through the perforated masking layer of the first masking layer. This is advantageous both for the curing of the optically clear adhesive (curing time, degree of curing) and for increasing the transmission of visible light. Depending on the application, it may be advantageous to design the perforations in the perforated masking layer of the first masking layer such that the total area of ​​the perforations is 10% to 90%, 20% to 80%, 30% to 70%, or 40% to 60%, in particular 10% to 30%, 20% to 40%, 30% to 50%, 40% to 60%, 50% to 70%, or 60% to 80% of the total area of ​​the perforated masking layer of the first masking layer.With a larger total perforation area, the curing of the uncured adhesive takes precedence; with a smaller total perforation area, the focus is on reduced transparency through the perforated masking layer for visible light. In practice, it can be advantageous to find a compromise between these conflicting properties. The area of ​​a perforation is determined by the laminated glass pane when viewed perpendicularly.

[0036] In an advantageous embodiment, the perforated masking layer area of ​​the first masking layer has a gradient with respect to the total area of ​​the perforations, relative to the total area of ​​the perforated masking layer area. The perforated masking layer area is designed such that the total area of ​​the perforations increases in a direction away from the edge of the composite disc or away from the non-perforated masking layer area, starting from the non-perforated masking layer area.Preferably, the total area of ​​the perforations in the perforated masking layer area, relative to the total area of ​​the perforated masking layer area, starting from the non-perforated masking layer area, in a direction away from the edge of the composite disc, increases from 10% to 90%, from 20% to 80%, from 30% to 70% or from 40% to 60%, in particular from 10% to 30%, from 20% to 40%, from 30% to 50%, from 40% to 60%, from 50% to 70% or from 60% to 80%.

[0037] In an advantageous embodiment, the perforated masking layer area of ​​the first masking layer exhibits a gradient in the density of the perforations, with the density of the perforations increasing in a direction away from the edge of the composite disc, starting from the non-perforated masking layer area. The "density" of the perforations is defined as the number of perforations per unit area. The unit area can be of any dimension, e.g., cm².2 or mm 2Since this is a relative design rule, the density of the perforations in the perforated masking layer area preferably increases, starting from the non-perforated masking layer area, in a direction away from the edge of the composite panel, from 10% to 90%, from 20% to 80%, from 30% to 70%, or from 40% to 60%, in particular from 10% to 30%, from 20% to 40%, from 30% to 50%, from 40% to 60%, from 50% to 70%, or from 60% to 80%. Advantageously, but not necessarily, the perforations are of the same size, i.e., they have the same area when viewed through. In an advantageous embodiment, the perforated masking layer area of ​​the first masking layer has a gradient in the size or area of ​​the perforations, wherein the area of ​​the perforations increases in a direction away from the edge of the composite disk, starting from the non-perforated masking layer area.Preferably, the area of ​​the perforations in the perforated masking layer region increases, starting from the non-perforated masking layer region and moving away from the edge of the composite disc, from 10% to 90%, from 20% to 80%, from 30% to 70%, or from 40% to 60%, in particular from 10% to 30%, from 20% to 40%, from 30% to 50%, from 40% to 60%, from 50% to 70%, or from 60% to 80%. Advantageously, but not necessarily, the density of the perforations remains unchanged.

[0038] In an advantageous embodiment, both the area of ​​the individual perforations and their density exhibit a corresponding gradient, i.e., a combination of the two immediately preceding embodiments is present.

[0039] Advantageously, the light transmission of the perforated masking layer area is at least 10% and at most 90%. Preferably, the light transmission of the perforated masking layer area is in the range of 10% to 90%, 20% to 80%, 30% to 70%, or 40% to 60%, in particular 10% to 30%, 20% to 40%, 30% to 50%, 40% to 60%, 50% to 70%, or 60% to 80%. With a gradient of perforations in the perforated masking layer area, the total area of ​​the perforations scales accordingly with respect to the total area of ​​the perforated masking layer area.

[0040] In an advantageous embodiment of the method according to the invention, the first masking layer is arranged on the first disk or between the first disk and the frame-shaped seal, including a region of the recess in which the optically clear adhesive is arranged, or on the second disk or between the second disk and the frame-shaped seal, including a region of the recess in which the optically clear adhesive is arranged. A second masking layer made of an opaque material without perforations, preferably forming a full surface, is arranged on the other disk or between the other disk and the frame-shaped seal, optionally including a portion of the recess in which the optically clear adhesive is arranged.It is particularly advantageous to apply the first masking layer to the third surface (III) of the second pane and the second masking layer to the second surface (II) of the first pane. This allows for time- and cost-efficient curing of the uncured, optically clear adhesive by means of the perforated masking layer area of ​​the first layer, while the second masking layer provides good privacy and also protects the underlying structures from UV radiation from the sun.

[0041] The first and second masking layers are preferably formed around the periphery of the composite disc. The peripheral edge of the composite disc borders the circumferential edge or end face of the composite disc. The first and second masking layers preferably have the same width, measured perpendicular to the stacking direction (away from the edge).

[0042] For example, the perforations can be round, oval, square, rectangular, or linear. These shapes are easy to produce. Preferably, the perforations have the same shape and / or size, and most preferably, the same shape and size.

[0043] In a preferred embodiment of the method according to the invention, the perforations are produced such that they are arranged in a uniform distribution across the perforated masking layer area of ​​the first masking layer. This measure advantageously enables uniform curing of the first adhesive layer across the entire area due to the uniformly distributed perforations. Particularly preferably, the perforations are uniformly distributed and have the same shape and size. In this case, with respect to a unit area of ​​the perforated masking layer area of ​​the first masking layer, there are always the same number of perforations of the same size and shape within that unit area, which is particularly advantageous for uniform curing of the optically clear adhesive.

[0044] The frame-shaped seal defines or surrounds a recess into which the uncured, optically clear adhesive is placed. In the stacking direction of the stack provided in step a), the recess is bounded by the planar structures arranged on both sides of the frame-shaped seal. These are, for example, the two discs or bonding layers made of a thermoplastic material, which are arranged on both sides of the frame-shaped seal. It is also possible that a bonding layer made of a thermoplastic material is arranged on only one side of the frame-shaped seal. In this case, the recess is bounded in the stacking direction by a disc and a bonding layer. The frame-shaped seal can, in principle, consist of any sealing material, as long as sufficient sealing of the recess for the uncured, optically clear adhesive in liquid form is ensured.The frame-shaped seal can, for example, consist of an acrylic-based adhesive and be designed in particular as an acrylic strip. The material of the frame-shaped seal can also consist, for example, of TPS (styrene block copolymer) or butyl rubber. It is also possible for the frame-shaped seal to consist of a thermoplastic material, preferably polyvinyl butyral (PVB). The frame-shaped seal can, in particular, be layered, i.e., in the form of a frame layer, especially a frame layer made of a thermoplastic material.

[0045] The intermediate layer of the stack provided in step a) comprises the frame-shaped seal with the uncured, optically clear adhesive arranged in the recess. In one embodiment, the intermediate layer does not include a bonding layer of thermoplastic material on either side of the frame-shaped seal (viewed in the stack direction). In an alternative embodiment, the intermediate layer comprises one or more (e.g., two) thermoplastic bonding layers, each consisting of a thermoplastic material and arranged on one or both sides of the frame-shaped seal (viewed in the stack direction).

[0046] In a preferred embodiment, the first masking layer is arranged on a thermoplastic compound layer.

[0047] In the inventive method, in step a) the first masking layer is produced such that the first masking layer has a perforated masking layer area and a non-perforated masking layer area. In the first masking layer, the perforations can be formed using a masking technique known per se when applying the first masking layer to the surface of the respective disc or to the surface of a thermoplastic compound layer.

[0048] In a preferred embodiment, the second masking layer is arranged on a thermoplastic bonding layer. If a second masking layer is provided and the first masking layer is arranged on a thermoplastic bonding layer between a disk and the frame-shaped seal, it is advantageous for the second masking layer to be arranged on the other disk or between the other disk and the frame-shaped seal on a thermoplastic bonding layer.

[0049] In a preferred embodiment of the method according to the invention, an electrical insert is arranged in the recess, in particular an electro-optical functional element with electrically controllable optical properties, especially an SPD functional film, a functional element based on liquid crystal technology, in particular a PDLC functional film, or an electrochromic functional element, a light source or a light guide or a photovoltaic module. Generally, the electrical insert is planar. The electrical insert has two surfaces (main surfaces) that are arranged substantially parallel to each other, as well as an edge surface running between them.

[0050] A particularly preferred electro-optical functional element is a liquid crystal-based element based on the so-called "guest-host" effect. Such functional elements typically comprise a nematic liquid crystal (host) equipped with an additive (guest), where the additive is, for example, dichroic dye molecules that absorb light anisotropically. Since the additive molecules have an elongated shape, their orientation can be controlled by the orientation of the liquid crystal molecules (i.e., host), which in practice is achieved by applying an electric field to the liquid crystal. In this way, for example, the optical transparency of the guest-host film can be very precisely controlled by an external electric field. This makes it particularly advantageous, for instance, to equip windshields with electrically switchable transparency, similar to a sun visor.

[0051] As practical experience has shown, guest-host films, due to their fluid-like physical properties, are very sensitive to mechanical stress caused by uneven contact pressure. Even the smallest local deviations in contact pressure during the lamination of the composite lens and in the laminated composite lens lead to the appearance of local optical defects in the guest-host films, which can render the composite lens unusable.

[0052] Guest-host films are well known to those skilled in the art, so they need not be discussed in detail here. Commercially, guest-host films are available, for example, under the name "light control film," such as from Dai Nippon Printing Co., Ltd., Japan, under the product name LCF005(EU). Preferably, the electrical insert arranged in the cavity is a guest-host film. The stack provided in step a) can, in principle, be produced using procedures known and common to those skilled in the art.

[0053] In a preferred embodiment of the method according to the invention, providing the stack in step a) comprises firmly connecting the frame-shaped seal, in particular a frame-shaped layer made of a thermoplastic material, directly to the second surface (II) of the first disk and directly to the third surface (III) of the second disk, in particular by lamination, wherein the recess is defined by the frame-shaped seal, the first disk and the second disk.

[0054] Creating at least one recess-inlet opening and at least one recess-outlet opening, each opening into the recess, in or on the frame-shaped seal,

[0055] Pouring the uncured, optically clear adhesive in liquid form into the recess through the at least one recess inlet opening, whereby gaseous substances contained in the recess can escape through the at least one recess outlet opening.

[0056] In the embodiment immediately above, the two panes are preferably prestressed glass panes, wherein the prestressing is preferably a thermal prestressing.

[0057] In a preferred embodiment of the method according to the invention, providing the stack in step a) comprises: firmly bonding a first bonding layer made of a thermoplastic material to the second surface (II) of the first disk and / or firmly bonding a second bonding layer made of a thermoplastic material to the third surface (III) of the second disk, in particular by lamination, as well as firmly bonding the frame-shaped seal, in particular a frame-shaped layer made of a thermoplastic material, to the first bonding layer and / or the second bonding layer, in particular by lamination, wherein the recess is defined by the frame-shaped seal, the first bonding layer and / or the second bonding layer.

[0058] Creating at least one recess inlet opening and at least one recess outlet opening, each leading into the recess, in or on the frame-shaped seal, filling the uncured, optically clear adhesive in liquid form into the recess through the at least one recess inlet opening, wherein gaseous substances contained in the recess can escape through the at least one recess outlet opening.

[0059] For the purposes of the present invention, the term "lamination" refers to the creation of a strong adhesive bond under the influence of heat, vacuum, and / or pressure. Methods known per se can be used. For example, lamination is carried out by autoclaving at an elevated pressure of approximately 10 to 15 bar and temperatures of 130 to 145 °C for a period of, for example, 2 hours. Compression in a calender between at least one pair of rollers is also possible. The temperature during the compression process is, for example, from 40 to 150 °C. Combinations of calender and autoclaving methods have proven particularly effective in practice. Alternatively, vacuum laminators can also be used.These laminators consist of one or more heated and evacuated chambers in which the panes are laminated over a period of, for example, approximately 60 minutes at a reduced pressure of 0.01 mbar to 800 mbar and a temperature of 80°C to 170°C. Vacuum bag or vacuum ring processes, which are known per se, operate, for example, at approximately 200 mbar and 80°C to 110°C. Lamination is also well known to those skilled in the art as a standard process in the industrial mass production of laminated glass panes, so it need not be discussed in more detail here.

[0060] Especially during lamination by autoclaving under high pressure, electrical inserts are subjected to high mechanical stress. Lamination is preferably carried out using a known vacuum heating process, i.e., a vacuum bag method, in which the stack is placed in a vacuum bag and heated in an oven.

[0061] During lamination, the frame-shaped seal, in particular a frame-shaped layer made of a thermoplastic material, is firmly bonded to the first bonding layer or directly to the first disc and / or to the second bonding layer or directly to the second disc, and the recess is sealed so that it can subsequently be filled with a non-cured, optically clear, liquid adhesive. All openings, with the exception of the recess inlet and outlet openings, must be sealed by softening the thermoplastic material so that it flows freely and fills all free air spaces, especially around the openings.The frame-shaped seal, in particular the frame-shaped layer, the first bonding layer, and / or the second bonding layer preferably contain or consist of one or more thermoplastic materials, selected according to one embodiment from polyvinyl butyral (PVB), ethylene vinyl acetate (EVA), and thermoplastic polyurethane (TPU). The first bonding layer, the second bonding layer, and / or the frame-shaped seal may optionally contain additives known to those skilled in the art, such as plasticizers. The aforementioned materials PVB, EVA, and TPU are preferred because they are frequently used and widely accepted in the automotive industry, and the use of conventional production facilities is at least partially possible. Furthermore, these materials are cost-effective.Particularly preferably, the first bonding layer, the second bonding layer and the frame-shaped seal, in particular the frame-shaped layer, consist of the same thermoplastic material, particularly preferably polyvinyl butyral (PVB), ethylene vinyl acetate (EVA) or thermoplastic polyurethane (TPU).

[0062] According to a preferred embodiment of the method according to the invention, the electrical insert is arranged in the recess such that it has direct contact with the first bonding layer or first glass pane, or with the second bonding layer or second glass pane, and no direct contact with the other bonding layer or glass pane. This measure enables direct contact with the optically clear adhesive on a main surface of the electrical insert, thereby offering process-related advantages.

[0063] According to a preferred embodiment of the method according to the invention, the electrical insert is arranged in the recess such that it has no direct contact with the frame-shaped seal. This measure advantageously allows direct contact of the optically clear adhesive with the edge surface of the electrical insert in order to protect the electrical insert from mechanical stress acting via the edge surface.

[0064] According to a preferred embodiment of the method according to the invention, the first masking layer is designed such that the perforated masking layer area extends to or partially covers the electrical insert, thus improving the aesthetic appearance of the composite disc. The bonding layer, which is directly connected to the disc on which the first masking layer is applied, or the bonding layer on which the first masking layer is applied, is at least largely transparent to electromagnetic radiation, preferably UV radiation, for curing the optically clear adhesive and, in particular, does not contain a UV blocker.In contrast, the other bonding layer, which is directly connected to the disc on which the first masking layer is not applied, or the other bonding layer on which the first masking layer is not applied, can be opaque to electromagnetic radiation, preferably UV radiation, for curing the optically clear adhesive and may in particular have a UV blocker.

[0065] In a preferred embodiment of the method according to the invention, the first masking layer with a perforated masking layer area is applied to the third surface (III) of the second disk, and the first bonding layer, which is bonded to the first disk, contains an electromagnetic radiation blocker for curing the optically clear adhesive, in particular a UV blocker. This embodiment has the particular advantage that the first adhesive area can be irradiated with electromagnetic radiation through the perforations, but on the other hand, the structures located below the first bonding layer are well protected from UV radiation from the sun in order to prevent premature aging.It is understood that the second bonding layer, which is directly and firmly connected to the second disk, is at least largely permeable to electromagnetic radiation, preferably UV radiation, for curing the optically clear adhesive and in particular does not contain a UV blocker.

[0066] In a preferred embodiment of the method according to the invention, at least one spacer, preferably in the form of an adhesive tape, is arranged in the recess, but outside the viewing area of ​​the composite pane. This is advantageous when the two panes are curved and manufacturing-related (minor) differences in the curvature of the two panes occur. Such a spacer ensures that the two panes do not touch in the area of ​​the recess.

[0067] The invention also extends to a laminated glass pane produced by the inventive method. The foregoing descriptions of the inventive method apply accordingly to the laminated glass pane produced by the inventive method. The laminated glass pane therefore comprises a first pane (e.g., a glass pane) with a first surface (I) and a second surface (II), and a second pane (e.g., a glass pane) with a third surface (III) and a fourth surface (IV), wherein the first pane and the second pane are firmly bonded together by an intermediate layer. The intermediate layer contains a frame-shaped seal with a recess in which a cured, optically clear adhesive is arranged.

[0068] The panes of the laminated glass unit contain or consist of glass, particularly preferably flat glass, float glass, quartz glass, borosilicate glass, aluminosilicate glass, soda-lime glass, or clear plastics, preferably rigid clear plastics, in particular polyethylene, polypropylene, polycarbonate, polymethyl methacrylate, polystyrene, polyamide, polyester, polyvinyl chloride and / or mixtures thereof. Suitable glasses are known, for example, from EP 0 847 965 B1. The panes can be clear, tinted, or colored. The first pane and the second pane can be independently unstressed, partially stressed, or stressed. If at least one of the panes is to have a stress, this can be a thermal or chemical stress.

[0069] If the laminated glass is used as a windshield, it should have sufficient light transmission in the central field of vision, preferably at least 70% in the main viewing area A according to ECE-R43. The first and second panes can also be referred to as the outer and inner panes.

[0070] The composite disc according to the invention is preferably curved in one or more directions in space, as is common for automotive windshields, with typical radii of curvature ranging from about 10 cm to about 40 m. However, the composite disc can also be flat, for example, if it is intended as a windshield for buses, trains, or tractors.

[0071] The first pane, the second pane, and / or the intermediate layer may have further suitable, known coatings, such as anti-reflective coatings, non-stick coatings, anti-scratch coatings, photocatalytic coatings, solar control coatings, or low-E coatings. It is understood that such a coating must not interfere with the electromagnetic radiation used to cure the optically clear adhesive. Therefore, not all coatings can be present at arbitrary locations, depending on which electromagnetic radiation is used to cure the optically clear adhesive. The thickness of the first and second panes can vary widely and thus be adapted to the specific requirements.The first and second panes advantageously have standard thicknesses of 0.7 mm to 25 mm, preferably 1.4 mm to 2.5 mm for vehicle glass, and preferably 4 mm to 25 mm for furniture, appliances, and buildings, particularly for electric radiators. The size of the panes can vary widely and depends on the size of the application according to the invention. For example, the first and second panes have surface areas of 200 cm², which are common in vehicle construction and architecture. 2 up to 20 m 2 on.

[0072] The laminated glass can be used to separate an interior space from the outside environment in an opening of a building or a window opening of a vehicle.

[0073] Furthermore, the invention extends to the use of the composite disc according to the invention in buildings or in means of transport for traffic on land, in the air or on water, in particular in motor vehicles, for example as a windshield, rear window, side window and / or roof window, especially in a passenger car or truck.

[0074] The various embodiments of the invention can be implemented individually or in any combination. In particular, the features mentioned above and explained below can be used not only in the combinations specified, but also in other combinations or individually, without departing from the scope of the present invention.

[0075] The above statements relating to the inventive method for manufacturing a composite disc apply analogously to the inventive composite disc. Similarly, the statements relating to the inventive composite disc apply analogously to the inventive method for manufacturing a composite disc.

[0076] The invention is explained in more detail below with reference to exemplary embodiments, with reference to the accompanying figures. These show, in simplified, schematic and not to scale, the following:

[0077] Figure 1 shows a cross-section through an embodiment of the composite disc according to the invention, Figure 2 shows a top view of an embodiment of the first masking layer of the composite disc of Figure 1 ,

[0078] Figure 3 shows a top view of another embodiment of the first masking layer of the composite disc of Figure 1.

[0079] Figure 4 shows a top view of a further embodiment of the first masking layer of the composite disc from Figure 1.

[0080] Figure 5 shows a top view of a further embodiment of the first masking layer of the composite disc from Figure 1.

[0081] Figure 6 shows a cross-section through an intermediate product for the manufacture of the composite disc of Fig. 1 ,

[0082] Figure 7 shows a cross-section through another intermediate product for the production of the composite disc of Fig. 1 ,

[0083] Figure 8 shows a flowchart of the process for manufacturing a composite disc according to the invention.

[0084] Let us first consider Figure 1, which illustrates an embodiment of the composite disc according to the invention by means of a cross-section. The section is parallel to the stacking direction of the composite disc.

[0085] The laminated pane, designated by the reference number 100, comprises a first pane 1 with a first surface (I) and a second surface (II), and a second pane 3 with a third surface (III) and a fourth surface (IV). In the laminated pane 100, the second surface (II) and third surface (III) face each other. The first surface (I) and the fourth surface (IV) face away from each other and form the outer surfaces of the laminated pane 100. The first pane 1 can also be referred to as the outer pane, and the second pane 3 as the inner pane. Both panes 1 and 3 are made, for example, of soda-lime glass and have a thickness of, for example, 1.4 mm to 2.5 mm. The laminated pane 100 is intended here, for example, as a transparent windshield, roof window, or side window of a motor vehicle. The first pane 1 and the second pane 3 are firmly bonded together by an intermediate layer 12.The intermediate layer 12 can be conceptually divided into different layers or layer-like areas. The intermediate layer 12 comprises a first bonding layer 2 made of a thermoplastic material, which is firmly bonded to the second surface (II) of the first disk 1; a second bonding layer 4 made of a thermoplastic material, which is firmly bonded to the third surface (III) of the second disk 3; and a frame-shaped seal 5 located between the first bonding layer 2 and the second bonding layer 4, and firmly bonded to them in direct contact. The frame-shaped seal 5 can be made of any sealing material, such as an acrylic-based adhesive, butyl rubber, or TPS, and can be designed, in particular, as an adhesive tape. It is also possible for the frame-shaped seal 5 to be made of a thermoplastic material.The frame-shaped seal 5, the first bonding layer 2, and the second bonding layer 4 together define a recess 8 in which a cured, optically clear adhesive 7 is arranged. Thus, the optically clear adhesive 7 is a component of the intermediate layer 12.

[0086] A planar electrical insert 6 is also accommodated in the recess 8. The electrical insert 6, which is, for example, an electro-optical functional element such as an SPD functional film, a PDLC functional film, or a liquid crystal-based functional element, is embedded in the intermediate layer 12. In the direction of gravity, the first bonding layer 2 is located above the frame-shaped seal 5 and above the electrical insert 6, and the second bonding layer 4 is located below the frame-shaped seal 5 and below the electrical insert 6.

[0087] Measured in the stacking direction, the thickness of the frame-shaped seal 5 is greater than the thickness of the electrical insert 6, wherein the recess 8 is formed by the cured, optically clear adhesive 7, the optically clear adhesive 7 being located between the first bonding layer 2 and the electrical insert 6 and being firmly bonded to them in direct contact, and between the electrical insert 6 and the second bonding layer 4 and being firmly bonded to them in direct contact.

[0088] The first bonding layer 2 and the second bonding layer 4 are made, for example, of PVB, EVA, or TPU. The frame-shaped seal 5 can also be made, for example, of PVB, EVA, or TPU. Preferably, the first bonding layer 2, the second bonding layer 4, and the frame-shaped seal 5 are made of the same thermoplastic material, preferably PVB, EVA, or TPU. The electrical insert 6 is planar and has a first main surface 9 and a parallel second main surface 10, between which the edge surface 11 is located. The first main surface 9 and the second main surface 10 face away from each other. The electrical insert 6 is arranged within the recess 8 such that its first main surface 9 is in direct contact with the first bonding layer 2 and has no direct contact with the second bonding layer 4.Furthermore, the electrical insert 6 within the recess 8 has no direct contact with the frame-shaped seal 5. The optically clear adhesive 7 is located between the edge surface 11 and the frame-shaped seal 5, and the optically clear adhesive 7 directly bonds the first bonding layer 2 and the second bonding layer 4 together in the area between the edge surface 11 and the frame-shaped seal 5.

[0089] The composite disc 100 has an end-face edge surface or border 26, which surrounds the composite disc 100.

[0090] On the third surface (III) of the second disk 3, a first masking layer 13 made of an opaque material 16 is arranged. The first masking layer 13 is formed around the periphery of the composite disk 100 (adjacent to the edge 26) and surrounds a transparent area of ​​the composite disk 100. The first masking layer 13 can also be referred to as a semi-transparent masking layer.

[0091] The first masking layer 13 has a non-perforated masking layer area 15 and a perforated masking layer area 14, or rather, it is composed of the non-perforated masking layer area 15 and the perforated masking layer area 14. In the perforated masking layer area 14, the opaque material 16 is provided with a plurality of perforations 25 (holes). The non-perforated masking layer area 15 is located between the edge 26 of the composite disc 100 and the perforated masking layer area 14. Thus, the perforated masking layer area 14 is positioned further inward than the non-perforated masking layer area 15, relative to the surface area of ​​the composite disc 100. The perforated masking layer area 14 borders directly on the non-perforated masking layer area 15.

[0092] The optically clear adhesive 7 has a first adhesive area 18 and a second adhesive area 19, wherein, with respect to the stacking direction of the stack or viewed perpendicularly through the composite disc 100, the first adhesive area 18 is covered by the perforated masking layer area 14, and the second adhesive area 19 is not covered by the first masking layer 13. In other words, the first masking layer 13, or the perforated masking layer area 14, covers the optically clear adhesive 7 in the first adhesive area 18, while in the second adhesive area 19, the optically clear adhesive 7 is clearly visible. The non-perforated masking layer area 15 of the first masking layer 13 extends (here, for example, from the edge 26) to the recess 8, without, however, covering the optically clear adhesive 7.

[0093] A second masking layer 17 made of an opaque material 16 is arranged on the second surface (II) of the first disc 1. Unlike the first masking layer 13, the second masking layer 17 has no perforations and is formed across its entire surface. The second masking layer 17 is formed around the periphery of the composite disc 100 and surrounds a transparent area of ​​the composite disc 100. The second masking layer 17 has a width perpendicular to the stacking direction of the composite disc 100 that corresponds, for example, to the width of the first masking layer 13. The second masking layer 17 can also be referred to as an opaque masking layer.

[0094] The first masking layer 13 and the second masking layer 17 completely cover the frame-shaped seal 5, relative to the stacking direction of the composite disc 100 and when viewed perpendicularly through the composite disc 100, respectively, and extend from the edge 26 into the recess 8. The perforated masking layer area 14 extends to the electrical insert 6 and partially covers it, for example, thus improving the aesthetic appearance.

[0095] The first bonding layer 2, for example, contains a UV blocker. The second bonding layer 4 does not contain a UV blocker.

[0096] The first masking layer 13 and the second masking layer 17 are printed here, for example, in the form of a cover print ("black print") using a printing process, in particular screen printing. An electrically non-conductive material, here for example a black-tinted (e.g., ceramic) screen printing ink, is used as the printing ink.

[0097] The perforations 25 are formed here, for example, in the form of round holes, with the perforations 25 in the perforated masking layer area 14 being, for example, uniformly distributed with respect to the area of ​​the perforated masking layer area.

[0098] 14 are arranged. Reference is made to Figures 2 to 5, which illustrate various embodiments of the first masking layer 13 of the composite disc 100 of Figure 1 by means of top views. The first masking layer 13 surrounds a transparent area 20 of the composite disc 100.

[0099] The first masking layer 13 consists of a non-perforated masking layer area 15 and a perforated masking layer area 14. The perforations 25 are represented as colorless or white round holes, which are bordered by the black opaque material 16. As can be clearly seen in the top views, the perforations 25 in the first masking layer 13 are formed as individual holes that are not connected and are each completely bordered by the opaque material 16, at least in the inner area of ​​the first masking layer 13 (i.e., not the edge area).

[0100] As illustrated in Figures 2 to 4, the perforated masking layer area 14 of the first masking layer 13 can have a lower density (see Figure 2), a medium density (see Figure 3), or a higher density (see Figure 4[EHI]) of perforations 25. Here, "density" refers to the number of perforations 25 per (arbitrarily chosen) unit area.

[0101] As shown in Figure 5, the perforated masking layer area 14 of the first masking layer 13 can also have a gradient, whereby the size or area of ​​the perforations 25 increases inwards (in the direction away from the edge 26 of the composite disk 100). Thus, the total area of ​​the perforations 25 increases in the gradient. Likewise, it is possible to additionally or alternatively change the density of the perforations 25, with the density also increasing inwards.

[0102] By changing the density of perforations 25 and / or the size of the perforations 25, the total area of ​​the perforations 25 can be varied as desired. A larger total area of ​​the perforations 25 allows more radiation to pass through to cure the optically clear adhesive 7, and vice versa. Conversely, a larger total area of ​​the perforations 25 allows more visible light to pass through, thus improving the visibility of structures through the perforated masking layer area 14, and vice versa. This conflict of objectives can be resolved as desired for each specific application.

[0103] In the embodiment shown in Figure 2, the total area of ​​the perforations 25 is smaller than in the embodiments shown in Figures 3 and 4, with the focus here being on reduced transparency in the visible range. The curing time for the optically clear adhesive 7 may be longer. In the embodiment shown in Figure 3, the total area of ​​the perforations 25 is larger than in the embodiment shown in Figure 2, with the focus here being both on rapid curing of the optically clear adhesive 7 and on relatively low transparency in the visible range. The curing time for the optically clear adhesive 7 is shorter compared to the embodiment shown in Figure 2, under otherwise unchanged conditions. In the embodiment shown in Figure 4, the total area of ​​the perforations 25 is even larger than in the embodiment shown in Figure 3, with the focus here being on very rapid curing of the optically clear adhesive 7.The curing time of the optically clear adhesive 7 is further reduced compared to the embodiment of Figure 2 under otherwise unchanged conditions, while conversely, the transparency in the visible area increases. In the embodiment of Figure 5, the total area of ​​the perforations 25 increases inwards, which is very advantageous with regard to the curing of the optically clear adhesive 7, while conversely, the transparency in the visible area decreases towards the edge 26. In addition, a particularly inconspicuous transition is created between the perforated masking layer area 14 and the non-perforated masking layer area 15.

[0104] The manufacturing process for the composite disc 100 will now be explained in more detail.

[0105] Let us first consider Figure 6, which illustrates an intermediate product in the manufacture of the composite disc 100. A stack is initially provided in which the second surface (II) of the first disc 1 and the third surface (III) of the second disc 3 face each other. The frame-shaped seal 5 is arranged between the first bonding layer 2 and the second bonding layer 4 and is in direct contact with them. The electrical insert 6 is arranged within the recess 8. The electrical insert 6 does not have direct contact with the frame-shaped seal 5 and is therefore not fitted precisely into the recess 8. A recess inlet opening 21 and a recess outlet opening 22 are inserted into the frame-shaped seal 5, for example, opposite each other. These openings are each tubular (nozzle-shaped) and, passing through the frame-shaped seal 5, open into the recess 8.

[0106] As illustrated in Figure 6, the recess inlet opening 21 serves for filling with optically clear adhesive 7 in liquid form, while gaseous substances can escape through the recess outlet opening 22, thus enabling complete filling of the recess 8 with optically clear adhesive 7. This is indicated by the arrows in Figure 6. For example, the recess 8 can also be overfilled, so that some of the optically clear adhesive 7 escapes from the recess outlet opening 22, thereby ensuring complete filling of the recess 8. The optically clear adhesive 7 is in direct contact with the first bonding layer 2 and direct contact with the second bonding layer 4. Furthermore, the optically clear adhesive 7 is in direct contact with the second main surface 10 of the electrical insert element 6 and with its edge surface 11.The recessed inlet opening 21 and the recessed outlet opening 22 are removed after the optically clear adhesive 7 has been poured in. The liquid optically clear adhesive 7 can be cured, for example by UV radiation (see Figure 7), to permanently bond the first bonding layer 2 to the second bonding layer 4, thereby bringing the optically clear adhesive 7 into a solid state.

[0107] As illustrated in Figure 7 using a further intermediate product, UV lamps 23 are positioned side by side to cure the optically clear adhesive 7, in order to irradiate the (still uncured) optically clear adhesive 7 with UV radiation 24 across its entire surface. In the first adhesive area 18, the optically clear adhesive 7 is irradiated with UV radiation 24 through the perforations 25. In the second adhesive area 19, there is a clear line of sight to the optically clear adhesive 7, so that the optically clear adhesive 7 can be directly irradiated with UV radiation 24. Advantageously, the optically clear adhesive 7 can also be cured quickly and completely in the first adhesive area 18, thereby avoiding, in particular, mechanical stresses caused by uneven curing in the first adhesive area 18 and the second adhesive area 19. The composite disc 100 shown in Figure 1 is thus produced.

[0108] It should be noted that the intermediate product shown in Figure 6 can be produced by methods known to a person skilled in the art.

[0109] Figure 8 illustrates the method according to the invention by means of a flowchart. Steps a) and b) denote:

[0110] Step a)

[0111] Providing a stack comprising a first disk 1 with a first surface (I) and a second surface (II) and a second disk 3 with a third surface (III) and a fourth surface (IV), wherein the first disk 1 and the second disk 3 are firmly connected to each other by an intermediate layer 12, the intermediate layer 12 having a frame-shaped seal 5 with a recess 8, wherein a non-cured, optically clear adhesive 7 in liquid form is arranged in the recess 8, the optically clear adhesive 7 being curable by electromagnetic radiation, wherein a first masking layer 13 made of an opaque material is arranged on the first disk 1 or the second disk 3 or between the first disk 1 and the second disk 3, the masking layer having a non-perforated masking layer region 15 and a perforated masking layer region 14.wherein in the perforated masking layer area 14 the opaque material 16 has a plurality of perforations 25, wherein, with respect to a stacking direction, the optically clear adhesive 7 is divided into a first adhesive area 18 and a second adhesive area 19, wherein the first adhesive area 18 is covered by the perforated masking layer area 14 and the second adhesive area 19 is not covered by the first masking layer 13,

[0112] Step b)

[0113] Irradiation of the stack with electromagnetic radiation 24 to cure the optically clear adhesive 7, wherein the first adhesive region 18 and the second adhesive region 19 of the optically clear adhesive 7 are irradiated with the electromagnetic radiation 24, wherein the first adhesive region 18 is irradiated with the electromagnetic radiation 24 through the perforated masking layer region 14.

[0114] From the above explanations, it follows that the invention provides an improved method for manufacturing composite discs, particularly those with integrated electrical inserts. An area of ​​the optically clear adhesive covered by a masking layer, for example in the form of black printing, can be irradiated with electromagnetic radiation through the perforations to cure it. Complete curing of the concealed area of ​​the optically clear adhesive can be achieved quickly and reliably. In particular, mechanical stresses resulting from uneven and / or incomplete curing of the optically clear adhesive can be avoided, which is advantageous with regard to integrated electrical inserts.

[0115] Reference symbol:

[0116] 1 first disc

[0117] 2 first bonding layer

[0118] 3 second disc

[0119] 4 second bonding layer

[0120] 5 frame-shaped seals

[0121] 6 electrical insert

[0122] 7 optically clear adhesive

[0123] 8 Exclusion

[0124] 9 first main area

[0125] 10 second main area

[0126] 11 edge surface

[0127] 12 Intermediate shift

[0128] 13 first masking layer

[0129] 14 perforated masking layer area

[0130] 15 non-perforated masking layer area

[0131] 16 opaque materials

[0132] 17 second masking layer

[0133] 18 first adhesive area

[0134] 19 second adhesive area

[0135] 20 Viewing area

[0136] 21 Exit-Entry Opening

[0137] 22 Recess-Exit Opening

[0138] 23 UV lamps

[0139] 24 UV radiation

[0140] 25 perforations

[0141] 26 Rand

[0142] 100 composite disc

[0143] I first surface of the first disk

[0144] II second surface of the first disk

[0145] III third surface of the second disk

[0146] IV fourth surface of the second disk

Claims

Claims 1. Method for producing a composite disc (100), comprising the following steps: a) providing a stack comprising a first disc (1) with a first surface (I) and a second surface (II) and a second disc (3) with a third surface (III) and a fourth surface (IV), wherein the first disc (1) and the second disc (3) are firmly joined together by an intermediate layer (12), the intermediate layer (12) having a frame-shaped seal (5) with a recess (8), wherein an uncured, optically clear adhesive (7) in liquid form is arranged in the recess (8), the optically clear adhesive (7) being curable by electromagnetic radiation, wherein a first masking layer (13) made of an opaque material (16) is arranged on the first disc (1) or the second disc (3) or between the first disc (1) and the second disc (3),which has a non-perforated masking layer region (15) and a perforated masking layer region (14), wherein in the perforated masking layer region (14) the opaque material (16) has a plurality of perforations (25), wherein, with respect to a stacking direction, the optically clear adhesive (7) is divided into a first adhesive region (18) and a second adhesive region (19), wherein the first adhesive region (18) is covered by the perforated masking layer region (14) and the second adhesive region (19) is not covered by the first masking layer (13), b) irradiating the stack with electromagnetic radiation (24) to cure the optically clear adhesive (7), wherein the first adhesive region (18) and the second adhesive region (19) of the optically clear adhesive (7) are irradiated with the electromagnetic radiation (24),wherein the first adhesive area (18) is irradiated with the electromagnetic radiation (24) through the perforated masking layer area (14).

2. Method for manufacturing a composite disk (100) according to claim 1, wherein step a) comprises: Applying the first masking layer (13) with a perforated masking layer area (14) to the second surface (II) of the first disk (1) or the third surface (III) of the second disk (3), and Applying a second masking layer (17) made of an opaque material (16) without perforations to the other disc (1 , 3).

3. Method for manufacturing a composite disk (100) according to claim 1 or 2, wherein step a) comprises: Forming the perforations (25) in the perforated masking layer area (14) of the first masking layer (13) in a uniform distribution, and / or Forming the perforations (25) in the perforated masking layer area (14) of the first masking layer (13) such that the sum of the perforations is 10% to 90%, 20% to 80%, 30% to 70% or 40% to 60%, in particular 10% to 30%, 20% to 40%, 30% to 50%, 40% to 60%, 50% to 70% or 60% to 80% of the total area of ​​the perforated masking layer area (14), and / or Forming the perforations (25) in the perforated masking layer area (14) of the first masking layer (13) in a round, oval, square or rectangular shape or in line form, Forming the perforations (25) in the perforated masking layer area (14) of the first masking layer (13) with the same shape and / or size.

4. A method for producing a composite disc (100) according to claim 1 or 2, wherein in step a) the perforations (25) in the perforated masking layer area (14) of the first masking layer (13) are formed such that the summed area of ​​the perforations (25) has a gradient, wherein the summed area of ​​the perforations (25) increases in the direction away from the non-perforated masking layer area (15), wherein the summed area increases in particular from 10% to 90%, from 20% to 80%, from 30% to 70% or from 40% to 60%, in particular from 10% to 30%, from 20% to 40%, from 30% to 50%, from 40% to 60%, from 50% to 70% or from 60% to 80% of the total area of ​​the perforated masking layer area (14) increases.

5. Method for manufacturing a composite disc (100) according to one of claims 1 to 4, in which in step a) the first masking layer (13), and optionally a second masking layer (17), is printed onto the disc (1 , 3) ​​as a cover print using a printing process, in particular a screen printing process.

6. Method for manufacturing a composite disc (100) according to one of claims 1 to 5, in which step a) comprises: firmly joining the frame-shaped seal (5), in particular a frame-shaped layer made of a thermoplastic material, directly to the second surface (II) of the first disk (1 ) and directly to the third surface (III) of the second disk (3), in particular by lamination, wherein the recess (8) is defined by the frame-shaped seal (5), the first disk (1 ) and the second disk (3), Creating at least one recess-inlet opening (21) and at least one recess-outlet opening (22), each opening into the recess (8), in or on the frame-shaped seal (5), Pouring the uncured, optically clear adhesive (7) in liquid form into the recess (8) through the at least one recess inlet opening (21), wherein gaseous substances contained in the recess (8) can escape through the at least one recess outlet opening (22).

7. Method for manufacturing a composite disc (100) according to claim 6, wherein the discs (1 , 3) ​​are prestressed.

8. Method for producing a composite disc (100) according to any one of claims 1 to 5, wherein step a) comprises: firmly bonding a first bonding layer (2) made of a thermoplastic material to the second surface (II) of the first disc (1) and / or firmly bonding a second bonding layer (4) made of a thermoplastic material to the third surface (III) of the second disc (3), in particular by lamination, as well as firmly bonding the frame-shaped seal (5), in particular a frame-shaped layer made of a thermoplastic material, to the first bonding layer (2) and / or the second bonding layer (4), in particular by lamination, wherein the recess (8) is defined by the frame-shaped seal (5), the first bonding layer (2) and / or the second bonding layer (4), Creating at least one recess-inlet opening (21) and at least one recess-outlet opening (22), each opening into the recess (8), in or on the frame-shaped seal (5), Pouring the uncured, optically clear adhesive (7) in liquid form into the recess (8) through the at least one recess inlet opening (21), wherein gaseous substances contained in the recess (8) can escape through the at least one recess outlet opening (22).

9. Method for producing a composite disc (100) according to claim 8, in which the first masking layer (13) is applied to the third surface (III) of the second disc (3) and the first bonding layer (2), which is firmly bonded to the first disc (1), contains a blocker, in particular a UV blocker, for electromagnetic radiation for curing the uncured, optically clear adhesive (7).

10. Method for manufacturing a composite disc (100) according to one of claims 1 to 9, in which an electrical insert (6) is arranged in the recess (8), in particular an electro-optical functional element with electrically controllable optical properties, such as an SPD functional film, a functional element based on liquid crystal technology, in particular a PDLC functional film, or an electrochromic functional element, a light source or a light guide or a photovoltaic module 1 1. Composite disc (100), manufactured by the method according to one of claims 1 to 10 10, comprising a first disk (1) with a first surface (I) and a second surface (II) and a second disk (3) with a third surface (III) and a fourth surface (IV), wherein the first disk (1) and the second disk (3) are firmly connected to each other by an intermediate layer (12), the intermediate layer (12) comprising a frame-shaped seal (5) with a recess (8), wherein a cured, optically clear adhesive (7) is arranged in the recess (8), wherein a first masking layer (13) made of an opaque material is arranged on the first disk (1) or the second disk (3) or between the first disk (1) and the second disk (3), the masking layer having a non-perforated masking layer region (15) and a perforated masking layer region (14), wherein in the perforated masking layer region (14) the opaque material (16) has a plurality of perforations (25),wherein the optically clear adhesive (7) is divided into a first adhesive region (18) and a second adhesive region (19), wherein the first adhesive region (18) is covered by the perforated masking layer region (14) and the second adhesive region (19) is not covered by the first masking layer (13).

12. Composite disc (100) according to claim 1 1 , wherein the first masking layer (13) is arranged on the third surface (III) of the second disc (3) and a second masking layer (17) made of an opaque material (16) without perforations is arranged on the second surface (II) of the first disc (1 ).

13. Composite disc (100) according to claim 11 or 12, wherein the intermediate layer (12) comprises a first bonding layer (2) made of a thermoplastic material which is firmly bonded to the second surface (II), and / or a second bonding layer (4) made of a thermoplastic material which is firmly bonded to the third surface (III).

14. Composite disc (100) according to claim 13, wherein the intermediate layer (12) comprises a first bonding layer (2) made of a thermoplastic material, which is firmly bonded to the second surface (II), wherein the first masking layer (13) is applied to the The third surface (III) of the second pane (3) is applied, and the first bonding layer (2) contains a blocker, in particular a UV blocker, for electromagnetic radiation to cure the uncured, optically clear adhesive (7).

15. Use of the composite pane (100) according to one of claims 11 to 14 in buildings or in means of transport for traffic on land, in the air or on water, in particular in motor vehicles, for example as a windshield, rear window, side window and / or roof window.

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