Composite pane with functional insert part

Abstract

The present invention relates to a composite pane (100) with a functional insert part (9), at least comprising a first pane (1) with a first surface (I) and a second surface (II) and a second pane (2) with a third surface (III) and a fourth surface (IV), wherein the second surface (II) and the third surface (III) face one another, and comprising a first connecting layer (3), a frame layer (5) with a thickness and optionally a second connecting layer (4), which are arranged between the first pane (1) and the second pane (2), wherein the first connecting layer (3) is arranged between the first pane (1) and the frame layer (5), the optional second connecting layer (4) is arranged between the frame layer (5) and the second pane (2), the frame layer (5) has a cutout (6) which is used to form a receiving space (7) which consists of a first sub-region and a second sub-region directly adjacent to the first sub-region, and the composite pane (100) has at least two through-holes (8), which extend from the fourth surface (IV) to the second sub-region of the receiving space (7), and has a functional insert part (9) of a planar shape, with a thickness, and having a first main surface (10) and a second main surface (11) and an edge surface (12) extending therebetween, wherein the functional insert part (9) is arranged in the first sub-region of the receiving space (7) in such a way that it lies directly in contact with the first main surface (10) of the first connecting layer (3) or with the second main surface (11) of the optional second connecting layer (4) and completely fills the first sub-region, wherein the thickness of the frame layer (5) is greater than the thickness of the functional insert part (9), and has a layer of a cured optically clear adhesive (13), which completely fills the second sub-region and at least partially fills the through-holes (8).

Description

[0001] Composite disc with functional insert

[0002] The invention relates to a composite disc with a functional insert, a method for its manufacture and its use.

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

[0004] It is known to provide a composite disc with a functional insert embedded in the thermoplastic interlayer. Functional inserts are, for example, designed in the form of electro-optic 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 applied electrical voltage. Examples of electro-optic functional elements are SPD functional elements (SPD = Suspended Particle Device), which are known, for example, from EP 0876608 B1 and WO 2011033313 A1, PDLC functional elements (PDLC = Polymer Dispersed Liquid Crystal), which are known, for example, from DE 102008026339 A1, and guest-host functional elements.

[0005] Functional inserts are typically laminated between two thermoplastic bonding layers, usually of the same thickness, within a composite panel. To compensate for the thickness difference, a thermoplastic frame layer can be used, inserted between the two thermoplastic bonding layers and surrounding the functional insert like a frame. Thus, the functional insert is placed into a cutout in the frame layer, surrounded like a passe-partout to protect it from excessive mechanical stress during the lamination of the composite panel.

[0006] For example, WO 2007 / 122428 A1 describes the use of two thermoplastic PVB bonding layers, each 0.76 mm thick, and a PVB frame layer, each 0.38 mm thick, to integrate an SPD functional element into a composite disk. WO 2007 / 122429 A1 describes the same structure for liquid crystal-based functional elements.

[0007] Although the use of a frame layer can significantly reduce the mechanical stress on the functional insert, laminating the composite pane still places a mechanical load on the insert, especially when laminating curved panes, which is frequently the case. In particular, the two panes may have different curvatures due to manufacturing tolerances or because this is intentional. This can lead to reversible as well as irreversible defects in the functional insert, such as a damaged active layer in an electro-optical functional element. Certain functional inserts can also be particularly sensitive to mechanical stress, such as photovoltaic modules integrated into the composite pane, which can break during lamination.

[0008] WO 2024 / 028113 A1 discloses a method for manufacturing a laminated disc, wherein a first stacking sequence is provided comprising a first disc, a layer of a plastic and an electro-optical functional film surrounded by a layered frame made of a plastic, a second stacking sequence is formed by arranging a second disc with a separating film on the first stacking sequence, the second stacking sequence is laminated under the influence of heat, vacuum and / or pressure, the second disc and the separating film are removed from the laminated second stacking sequence, a viscous bead of adhesive is applied to the layered frame of the first stacking sequence, the bead of adhesive continuously surrounding the electro-optical functional film except for at least one interruption, and the second disc is arranged on the viscous bead of adhesive such thatthat a cavity enclosed by the adhesive bead is formed between the electro-optical functional film and the second disk, wherein the at least one interruption of the adhesive bead forms an opening of the cavity, the cavity is filled by injecting an optically transparent adhesive through the opening into the cavity, and the optically transparent adhesive is cured in the cavity.

[0009] In contrast, the object of the present invention is to provide an improved composite lens with an integrated functional insert and an improved method for manufacturing a composite lens with an integrated functional insert. The composite lenses should be producible in industrial series production with high optical quality and low reject rate.

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

[0011] The composite disc according to the invention with a functional insert comprises a first disc, a second disc, a first bonding layer, a frame layer, a functional insert, a layer of a cured optically clear adhesive and optionally a second bonding layer.

[0012] The discs each have two surfaces (main surfaces) designed for transparency, which are arranged essentially parallel to each other, as well as an intermediate edge surface. The first disc has a first surface and a second surface. The second disc has a third surface and a fourth surface.

[0013] The first bonding layer, the optional second bonding layer and the frame layer are arranged between the first disk and the second disk, wherein the first bonding layer is arranged between the first disk and the frame layer and the second bonding layer, if present, is arranged between the frame layer and the second disk.

[0014] The frame layer has a cutout that is bounded in the plane of the frame layer by the material of the frame layer; that is, the cutout is an internal cutout of the frame layer. The cutout of the frame layer is bounded by the first bonding film (on one side of the frame layer) and / or, if present, the second bonding film (on the other side of the frame layer), thus creating a receiving space. The cutout therefore forms a receiving space in the composite panel according to the invention. The receiving space consists of two sub-regions: a first sub-region and a second sub-region immediately adjacent to the first sub-region.

[0015] The functional insert is planar. It has two surfaces (main surfaces) that are arranged essentially parallel to each other, as well as an intermediate edge surface. According to the invention, the functional insert is arranged in the composite disc in the first sub-area of ​​the receiving space such that it completely fills this sub-area and directly abuts the first main surface of the first bonding layer or the second main surface of the optional second bonding layer. In embodiments where the composite disc does not have a second bonding layer, the functional insert directly abuts the first main surface of the first bonding layer.In embodiments in which the composite disc has a second bonding layer, the functional insert is directly adjacent to the first main surface of the first bonding layer or to the second main surface of the second bonding layer.

[0016] The functional insert has a certain thickness, and the frame layer also has a certain thickness. The thickness of the frame layer is chosen to be greater than the thickness of the functional insert. Therefore, the functional insert is not fitted precisely into the receiving space, but rather, as described above, is positioned in the first section of the receiving space and completely fills it. It is understood that the functional insert is not located in the second section of the receiving space and does not protrude into it.

[0017] According to the invention, the composite disc has at least two through holes which extend from the fourth surface to the second part of the receiving space.

[0018] According to the invention, the layer of a cured, optically clear adhesive completely fills the second part of the receiving space and at least partially fills the through-holes. In the composite disc, the receiving space is therefore not a cavity, since it contains the functional insert and the cured, optically clear adhesive. As described above, the second bonding layer is optional. In one embodiment of the composite disc according to the invention, the composite disc does not have a second bonding layer and is thus a composite disc comprising at least

[0019] - a first disk with a first surface and a second surface and a second disk with a third surface and a fourth surface, wherein the second surface and the third surface face each other,

[0020] - a first bonding layer and a frame layer of thickness, which are arranged between the first disk and the second disk, wherein the first bonding layer is arranged between the first disk and the frame layer, the frame layer has a cutout through which a receiving space is formed, consisting of a first sub-area and a second sub-area immediately adjacent to the first sub-area, and the composite disk has at least two through-holes extending from the fourth surface to the second sub-area of ​​the receiving space,

[0021] - a functional insert with a planar shape and thickness, comprising a first main surface and a second main surface, as well as an intermediate edge surface, wherein the functional insert is arranged in the first sub-area of ​​the receiving space such that it directly abuts the first main surface of the first connecting layer and completely fills the first sub-area, wherein the thickness of the frame layer is greater than the thickness of the functional insert, and

[0022] - a layer of a cured, optically clear adhesive that completely fills the second sub-area and at least partially fills the through-holes.

[0023] In an alternative embodiment of the composite disc according to the invention, which is preferred, the composite disc has a second bonding layer and is thus a composite disc comprising at least

[0024] - a first disk with a first surface and a second surface and a second disk with a third surface and a fourth surface, wherein the second surface and the third surface face each other,

[0025] - a first bonding layer, a second bonding layer and a frame layer of thickness, which are arranged between the first disk and the second disk, wherein the first bonding layer is arranged between the first disk and the frame layer, the second bonding layer is arranged between the frame layer and the second disk, the frame layer has a cutout through which a receiving space is formed, consisting of a first sub-area and a second sub-area immediately adjacent to the first sub-area, and the composite disk has at least two through-holes extending from the fourth surface to the second sub-area of ​​the receiving space,

[0026] - a functional insert with a planar shape and thickness, comprising a first main surface and a second main surface, as well as an intermediate edge surface, wherein the functional insert is arranged in the first sub-area of ​​the receiving space such that it directly abuts the first main surface of the first connecting layer or the second main surface of the second connecting layer and completely fills the first sub-area, wherein the thickness of the frame layer is greater than the thickness of the functional insert, and

[0027] - a layer of a cured, optically clear adhesive that completely fills the second sub-area and at least partially fills the through-holes.

[0028] In a preferred embodiment of the composite disc according to the invention, the at least two through-holes, when viewed through the composite disc from the fourth surface, lie outside the area in which the functional insert is arranged. Thus, the through-holes, when viewed perpendicularly through the composite disc or in orthogonal projection through the composite disc, are not in overlap or overlap with the functional insert. The through-holes therefore have no section that overlaps the functional insert.

[0029] In a preferred embodiment of the composite disk according to the invention, the composite disk has exactly two through holes which are arranged diagonally opposite each other.

[0030] In an alternative preferred embodiment, the composite disk has exactly four through holes, two of which are arranged diagonally opposite each other.

[0031] In further embodiments, the composite disc can also have more than four through-holes. In a preferred embodiment of the composite disc according to the invention, the functional insert is an electrical insert element, in particular an electro-optical functional element with electrically controllable optical properties, in particular an SPD functional element, a functional element based on liquid crystal technology, in particular a PDLC functional element, a guest-host functional film or an electrochromic functional element, a light source or a light guide or a photovoltaic module.

[0032] A particularly preferred functional insert is a guest-host functional film, i.e., a liquid crystal-based functional element based on the so-called "guest-host" effect. Such functional elements typically comprise a nematic liquid crystal (host) modified with an additive (guest), where, for example, dichroic dye molecules are used as the additive, which 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.For example, windshields can be very advantageously equipped with an electrically switchable transparency in the manner of a sun visor.

[0033] Guest-host functional slides are well known to experts, so they do not need to be discussed in more detail here.

[0034] The frame layer can consist of a single frame-shaped layer or of two frame-shaped layers.

[0035] In a preferred embodiment of the composite disc according to the invention, the frame layer consists of only a single frame-shaped layer. In this embodiment, the frame layer thus consists of a first frame-shaped layer with a recess. In this embodiment, the recess in the first frame-shaped layer therefore corresponds to the cutout in the frame layer through which a receiving space is formed. Particularly preferred in this embodiment is the arrangement of the functional insert in the recess such that its edge surface has no direct contact with the first frame-shaped layer.In an alternative preferred embodiment of the composite disc according to the invention, the frame layer consists of two frame-shaped layers, namely a first frame-shaped layer with a recess and a second frame-shaped layer with a recess, which are arranged one above the other over a surface. The functional insert is arranged in the recess in the first frame-shaped layer such that its edge surface has no direct contact with the first frame-shaped layer and no direct contact with the second frame-shaped layer. In this embodiment, the recesses in the first frame-shaped layer and in the second frame-shaped layer are preferably arranged in complete overlap when viewed perpendicularly through the composite disc.In this embodiment, the recess in the first frame-shaped layer and the recess in the second frame-shaped layer together form the cutout in the frame layer through which a receiving space is formed.

[0036] In an alternative preferred embodiment of the composite disc according to the invention, the frame layer consists of two frame-shaped layers, namely a first frame-shaped layer with a recess and a second frame-shaped layer with a recess, which are arranged one above the other over a surface. The functional insert is arranged in the recess in the first frame-shaped layer such that its edge surface has direct contact with the first frame-shaped layer and no direct contact with the second frame-shaped layer. In this embodiment, the recess in the first frame-shaped layer is thus smaller, viewed perpendicularly through the composite disc, than the recess in the second frame-shaped layer and lies entirely within the area in which the recess in the second frame-shaped layer is located.In this embodiment, the recess in the first frame-shaped layer and the recess in the second frame-shaped layer together form the cutout in the frame layer through which a receiving space is formed.

[0037] The recess in the first frame-shaped layer is bounded in the plane of the first frame-shaped layer by the material of the first frame-shaped layer; that is, the recess is an internal recess in the first frame-shaped layer. The recess in the second frame-shaped layer is bounded in the plane of the second frame-shaped layer by the material of the second frame-shaped layer; that is, the recess is an internal recess in the second frame-shaped layer. In embodiments of the composite disc according to the invention, in which the functional insert is arranged in the recess in the first frame-shaped layer such that it has no direct contact with the first frame-shaped layer, cured optically clear adhesive is arranged between the functional insert and the first frame-shaped layer.

[0038] In embodiments of the composite disc according to the invention, in which the frame layer consists of a first frame-shaped layer with a recess and a second frame-shaped layer with a recess, and the functional insert is arranged in the recess in the first frame-shaped layer in such a way that it has direct contact with the first frame-shaped layer, the recess in the first frame-shaped layer has the same external dimensions as the functional insert, so that the functional insert is arranged precisely in the recess and has direct contact with the edge surface to the first frame-shaped layer.

[0039] In embodiments in which the frame layer consists of a first frame-shaped layer with a recess and a second frame-shaped layer with a recess, and the functional insert is arranged in the recess in the first frame-shaped layer, the thickness of the first frame-shaped layer is preferably equal to the thickness of the functional insert when viewed perpendicularly through the composite disk.

[0040] In a particularly preferred embodiment, the functional insert is in direct contact with the first main surface of the first bonding layer.

[0041] The first frame-shaped layer preferably contains or consists of at least one thermoplastic polymer, particularly preferably ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), or thermoplastic polyurethane (TPU), or mixtures, copolymers, or derivatives thereof, most preferably PVB. Alternatively, the first frame-shaped layer can be an adhesive layer based on an acrylate, a styrene block copolymer (TPS), or butyl adhesive. Suitable materials for the first frame-shaped layer are known to those skilled in the art.

[0042] The second frame-shaped layer preferably contains at least one thermoplastic

[0043] The second frame-shaped layer is a polymer, particularly preferably ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), or thermoplastic polyurethane (TPU), or mixtures, copolymers, or derivatives thereof, most preferably PVB. Alternatively, the second frame-shaped layer can be an adhesive layer based on an acrylate, a styrene block copolymer (TPS), or butyl adhesive. Suitable materials for the second frame-shaped layer are known to those skilled in the art. The second frame-shaped layer preferably has a thickness of 0.2 mm to 2 mm, more preferably 0.3 mm to 0.6 mm, and most preferably 0.4 mm to 0.5 mm.

[0044] The first and second bonding layers each contain, independently of one another, at least one thermoplastic polymer, preferably ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), or thermoplastic polyurethane (TPU), or mixtures, copolymers, or derivatives thereof, particularly preferably PVB. The thickness of the first and second bonding layers is preferably from 0.2 mm to 2 mm, particularly preferably from 0.3 mm to 1 mm, for example, 380 pm, 760 pm, or 848 pm. The first and second bonding layers can be formed independently of one another by a single film or by more than one film. The first and / or second bonding layer can also be a film with functional properties, for example, a film with acoustic damping properties.

[0045] The at least two through holes preferably have a diameter between 1 mm and 15 mm, preferably between 3 mm and 12 mm, and particularly preferably between 5 mm and 10 mm, independently of each other.

[0046] Optically clear adhesives (OCA = Optically Clear Adhesive) are well known to professionals. This is especially true for liquid optically clear adhesives (LOCA = Liquid Optically Clear Adhesive), which are commercially available from a wide variety of suppliers. Optically clear adhesives are 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 or to connect plastic covers to touch-sensitive displays. Depending on the type of liquid optically clear adhesive used, it can be thermally cured (i.e., heated).curable by heat input), by electromagnetic radiation, in particular UV radiation, IR radiation or microwave radiation, by ultrasound, by moisture input or by a chemical reaction of different components (in particular 2-component adhesive).

[0047] In a preferred embodiment, the bonding layer between the first and second bonding layers to which the functional insert directly rests comprises a UV blocker. In embodiments where the cured optically clear adhesive is an optically clear adhesive cured by UV radiation, the bonding layer between the first and second bonding layers to which the functional insert does not directly rest does not comprise a UV blocker.

[0048] 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.

[0049] The first and second panes of the laminated glass unit contain or consist independently of each other of glass, particularly preferably flat glass, float glass, quartz glass, borosilicate glass, aluminosilicate glass, soda-lime glass, or of clear plastics, preferably rigid clear plastics, in particular polyethylene, polypropylene, polycarbonate, polymethyl methacrylate, polystyrene, polyamide, polyester, polyvinyl chloride and / or mixtures thereof. Preferably, the first and second panes consist of glass, particularly preferably soda-lime glass, as is common for window panes.

[0050] The panes can be clear, tinted, or colored. If the laminated pane 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. It is understood that the specified light transmission refers to the light transmission of the laminated pane with the functional insert in its transparent state. The first pane and the second pane can also be referred to as the outer and inner panes, respectively, with the first pane preferably being the outer pane and the second pane preferably being the inner pane.

[0051] The laminated glass is particularly intended for separating the interior from the outside environment in an opening of a building or in a window opening of a vehicle. For the purposes of the invention, the term "inner glass" refers to the glass of the laminated glass facing the interior. The term "outer glass" refers to the glass facing the outside environment.

[0052] Preferably, the first pane of the composite pane according to the invention is the outer pane in its installed position, and the second pane is the inner pane. The first pane is thus preferably suited to face the outer environment in its installed position, and the second pane is thus preferably suited to face the inner environment in its installed position.

[0053] The first and second panes can have suitable coatings known per se, for example anti-reflective coatings, non-stick coatings, anti-scratch coatings, photocatalytic coatings, sun protection coatings, or low-E coatings.

[0054] The thickness of the first and second panes can vary widely and thus be adapted to the specific requirements. Advantageously, the first and second panes 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 functional 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 areas of 200 cm², which are common in vehicle construction and architecture. 2 up to 20 m 2 on.

[0055] The invention also relates to a method for manufacturing a composite disc according to the invention with a functional insert.

[0056] The method according to the invention comprises, as a first step, a) the provision of a composite. The composite comprises a first disk with a first surface and a second surface, a first bonding layer, a frame layer with a thickness of, a functional insert with a thickness of, a second disk with a third surface and a fourth surface, and optionally a second bonding layer. The functional insert has a planar shape and a first main surface, a second main surface, and an intermediate edge surface. The frame layer has a cutout.In this composite structure, the second and third surfaces face each other, the frame layer is positioned between the first and second panes, the first bonding layer is positioned between the first pane and the frame layer, and, if present, the second bonding layer is positioned between the frame layer and the second pane. The thickness of the frame layer is greater than the thickness of the functional insert.

[0057] The cutout in the frame layer creates a recording space consisting of a first sub-area and a second sub-area immediately adjacent to the first sub-area.

[0058] In the assembly, the functional insert is arranged in the first sub-area of ​​the receiving space in such a way that it directly abuts the first main surface of the first connecting layer or the second main surface of the optional second connecting layer and completely fills the first sub-area.

[0059] The assembly has at least two through holes extending from the fourth surface to the second sub-area of ​​the receiving space.

[0060] As a subsequent second step b), the method according to the invention comprises filling an optically clear adhesive in liquid form into the receiving space of the composite through at least one of the at least two through-holes, wherein gaseous substances contained in the receiving space can escape through at least one other of the at least two through-holes. The filling is carried out in such a way that the optically clear adhesive completely fills the second partial area and at least partially fills the through-holes.

[0061] In a third step c) following the second step, the method according to the invention comprises curing the optically clear adhesive. The optically clear adhesive used in the method according to the invention is, in particular, curable, i.e., it can be irreversibly brought into a cured state. Typically, it is a plastic that is brought into a polymer-crosslinked state by curing. This distinguishes such an optically clear adhesive significantly from a thermoplastic material, which, although also optically transparent, can always be softened again (i.e., reversibly) by the application of heat and, in particular, brought into a flowable state. In contrast, the optically clear adhesive preferably cannot be brought back into a softened and, in particular, a flowable state once it has cured.The optically clear adhesive is therefore preferably not a thermoplastic. Alternatively, a thermoplastic optically clear adhesive could be used, but this is not preferred.

[0062] Depending on the type of optically clear adhesive, curing can occur through thermal curing (i.e., heat application), electromagnetic radiation, especially UV, IR, or microwave radiation, ultrasound, moisture application, or a chemical reaction of various components (especially two-component adhesives). The curing time of the optically clear adhesive can be influenced by temperature in many curing processes. In particular, curing can be accelerated by heat application. Conversely, curing can be slowed down by cooling. Therefore, the curing time can be controlled, for example, by heating or cooling the optically clear adhesive.

[0063] The filling of the optically clear liquid adhesive in step b) is carried out, in particular, via a connecting line which is attached to the second disc by means of a filling port in the area of ​​a through-hole and extends from the through-hole to a metering unit for liquid optically clear adhesive. The escape of the gaseous substances in step b) is carried out, in particular, via a line which is attached to the second disc in the area of ​​another through-hole by means of a venting port.

[0064] The seal between the connecting pipe and the second disc, and between the pipe and the second disc, can be achieved, for example, by means of a rubber seal or a so-called press-fit connection. The filling port and the venting port are preferably supported by means of support devices.

[0065] Preferably, support devices are also arranged on the first surface of the first pane to prevent slippage of the composite and / or glass breakage during the filling process with the optically clear liquid adhesive. The support devices on the first surface of the first pane are preferably arranged, when viewed perpendicularly through the composite or in orthogonal projection through the composite, overlapping the filling port or the venting port, respectively. In this way, the impulse occurring during the filling of the liquid, optically clear adhesive can be compensated, thus preventing slippage of the composite and / or glass breakage during the filling process.

[0066] It is understood that the connecting pipe, which is attached to the second disc via a filling port, and the pipe, which is attached to the second disc via a venting port, are only removed after the optically clear adhesive has completely cured. If, after the liquid clear adhesive has been poured into the second section of the receiving chamber, the connecting pipe and the pipe are cut and sealed using a gripper with a cutting blade, removal can optionally also take place after sealing the connecting pipe and the pipe, but before the optically clear adhesive has cured.

[0067] The connecting cable and the cable are preferably made of aluminum, stainless steel, or plastic, particularly aluminum or stainless steel. Particularly preferably, the connecting cable and the cable are made of plastic.

[0068] The support devices are preferably made of a metal, in particular aluminum or stainless steel.

[0069] The seals are preferably rubber seals.

[0070] In a preferred embodiment of the method according to the invention, the first step a) comprises the following steps: a1) providing the first disk, the second disk, the first bonding layer, the second bonding layer, a first frame-shaped layer with a recess, and the functional insert, wherein the second bonding layer has at least two holes and the second disk has at least two holes; a2) producing a first stack of layers comprising the first disk and the second disk, wherein the second surface and the third surface are facing each other, with the first bonding layer and the second bonding layer interposed, wherein the first bonding layer is positioned immediately adjacent to the first disk and the second bonding layer is positioned immediately adjacent to the second disk.that each hole in the second bonding layer and a hole in the second disk form a common through-hole, wherein a separating film is arranged between the first bonding layer and the second bonding layer, the first frame-shaped layer is arranged between the separating film and the first bonding layer or between the separating film and the second bonding layer, the functional insert is arranged in the recess in the first frame-shaped layer, and placeholders are arranged in the through-holes, a3) Laminating the first stack of layers to firmly bond the first disk to the first bonding layer and to firmly bond the second disk to the second bonding layer and to firmly bond the functional insert and the first frame-shaped layer to the first bonding layer or the second bonding layer, thereby forming a first pre-composite consisting of the first disk,a) the first bonding layer, the first frame-shaped layer and the functional insert, and a second pre-composite consisting of the second disk and the second bonding layer, or a first pre-composite consisting of the first disk and the first bonding layer and a second pre-composite consisting of the second disk and the second bonding layer, the first frame-shaped layer and the functional insert, a4) separating the first pre-composite from the second pre-composite at the release film and removing the release film, a5) producing a second stack of layers comprising the first pre-composite and the second pre-composite, wherein the second surface and the third surface are facing each other and optionally a second frame-shaped layer with a recess between the first pre-composite and the second pre-composite is arranged, a6) joining the second stack of layers, in particular by lamination in an autoclave,a7) Removing the placeholders from the through holes.

[0071] It is understood that steps a1) to a7) are carried out in the specified order.

[0072] In one embodiment of the previously described method, no second frame-shaped layer is arranged between the first pre-composite and the second pre-composite in step a5). In this embodiment, the frame layer of the composite disc produced by the method thus consists of the first frame-shaped layer. Since, according to the invention, the thickness of the frame layer is greater than the thickness of the functional insert, in this embodiment, in which the frame layer consists of the first frame-shaped layer, the thickness of the first frame-shaped layer is therefore greater than the thickness of the functional insert.

[0073] In an alternative embodiment of the previously described method, a second frame-shaped layer is arranged between the first and second pre-composites in step a5). In this embodiment, the frame layer of the composite disc produced by the method thus consists of the first and second frame-shaped layers. Preferably, in this embodiment, the thickness of the first frame-shaped layer corresponds to the thickness of the functional insert. Furthermore, in this embodiment, the recess in the first frame-shaped layer preferably has the same outer dimensions as the functional insert, so that the functional insert is preferably arranged precisely in the recess.

[0074] In an alternative preferred embodiment of the method according to the invention, the first step a) comprises the following steps: a1) providing the first disk, the second disk, the first bonding layer, a first frame-shaped layer with a recess, and the functional insert, wherein the second disk has at least two holes; a2) producing a first stack of layers comprising the first disk and the second disk, wherein the second surface and the third surface are facing each other, with the first bonding layer interposed, wherein the first bonding layer is positioned immediately adjacent to the first disk, wherein a separating film is arranged between the first bonding layer and the second disk, the first frame-shaped layer is arranged between the separating film and the first bonding layer, and the functional insert is arranged in the recess in the first frame-shaped layer.the holes in the second disk form through holes and placeholders are arranged in the through holes, a3) Laminating the first stack of layers to firmly bond the first disk to the first bonding layer and to firmly bond the functional insert and the first frame-shaped layer to the first bonding layer, thereby producing a first pre-composite consisting of the first disk, the first bonding layer, the first frame-shaped layer and the functional insert and a second pre-composite consisting of the second disk, a4) Separating the first pre-composite from the second pre-composite at the release film and removing the release film, a5) Producing a second stack of layers comprising the first pre-composite and the second pre-composite,wherein the second surface and the third surface are facing each other and optionally a second frame-shaped layer with a recess is arranged between the first pre-composite and the second pre-composite, a6) joining the second layer stack, in particular by lamination in an autoclave, a7) removing the placeholders from the through holes.

[0075] It is understood that steps a1) to a7) are carried out in the specified order.

[0076] In an alternative preferred embodiment of the method according to the invention, the first step a) comprises the following steps: a1) providing the first disk, the second disk, the first bonding layer, the second bonding layer, and the functional insert, wherein the second bonding layer has at least two holes and the second disk has at least two holes, a2) producing a first stack of layers comprising the first disk and the second disk, wherein the second surface and the third surface are facing each other with the first bonding layer and the second bonding layer interposed, wherein the first bonding layer is positioned immediately adjacent to the first disk and the second bonding layer is positioned immediately adjacent to the second disk,that each hole in the second bonding layer and a hole in the second disk form a common through-hole, wherein two separating films are arranged between the first bonding layer and the second bonding layer, a third frame-shaped layer with a recess is arranged between the two separating films, and the functional insert is arranged in the recess in the third frame-shaped layer such that it directly abuts the first main surface of the first bonding layer or the second main surface of the second bonding layer, and placeholders are arranged in the through-holes, a3) Laminating the first stack of layers to firmly bond the first disk to the first bonding layer, to firmly bond the second disk to the second bonding layer, and to firmly bond the functional insert to the first bonding layer or the second bonding layer.a third pre-assembly consisting of the first disk, the first bonding layer and the functional insert, and a fourth pre-assembly consisting of the second disk and the second bonding layer, or a third pre-assembly consisting of the first disk and the first bonding layer, and a fourth pre-assembly consisting of the second disk and the second bonding layer and the functional insert, a4) separating the third pre-assembly from the fourth pre-assembly at the separating films and removing the separating films and the third frame-shaped layer, a5) producing a second stack of layers comprising the third pre-assembly and the fourth pre-assembly, wherein the second surface and the third surface are facing each other and a frame layer with a cutout is arranged between the third pre-assembly and the fourth pre-assembly such that the functional insert is arranged in the cutout, a6) joining the second stack of layers,in particular by lamination in an autoclave, a7) removal of the placeholders from the through holes.

[0077] It is understood that steps a1) to a7) are carried out in the specified order.

[0078] In an alternative preferred embodiment of the method according to the invention, the first step a) comprises the following steps: a1) providing the first disk, the second disk, the first bonding layer, and the functional insert, wherein the second disk has at least two holes; a2) producing a first stack of layers comprising the first disk and the second disk, wherein the second surface and the third surface are facing each other, with the first bonding layer interposed, wherein the first bonding layer is positioned immediately adjacent to the second surface of the first disk, wherein a separating film is arranged between the first bonding layer and the second disk, a third frame-shaped layer with a recess is arranged between the separating film and the second disk, and the functional insert is arranged in the recess in the third frame-shaped layer such thatthat it directly abuts the first main surface of the first bonding layer, the holes in the second disk form through holes and wherein placeholders are arranged in the through holes, a3) Laminating the first stack of layers to firmly bond the first disk to the first bonding layer and to firmly bond the functional insert to the first bonding layer, thereby producing a third pre-composite from the first disk, the first bonding layer and the functional insert and a fourth pre-composite from the second disk, a4) Separating the third pre-composite from the fourth pre-composite at the release film and removing the release film and the third frame-shaped layer, a5) Producing a second stack of layers comprising the third pre-composite and the fourth pre-composite,wherein the second surface and the third surface are facing each other and a frame layer with a cutout is arranged between the third pre-composite and the fourth pre-composite such that the functional insert is arranged in the cutout, a6) joining the second layer stack, in particular by lamination in an autoclave, a7) removing the placeholders from the through holes.

[0079] It is understood that steps a1) to a7) are carried out in the specified order.

[0080] The third frame-shaped layer preferably contains or consists of at least one thermoplastic polymer, particularly preferably ethylene vinyl acetate (EVA), polyvinyl butyral (PVB), or thermoplastic polyurethane (TPU), or mixtures, copolymers, or derivatives thereof, most preferably PVB. Alternatively, the third layer may contain or consist of polyethylene terephthalate (PET) or polyethylene (PE), or, for example, Teflon or polyvinyl fluoride (PVF). The third frame-shaped layer has a thickness, wherein the thickness of the third frame-shaped layer is preferably at least equal to the thickness of the functional insert, i.e., the thickness of the third frame-shaped layer is preferably equal to or greater than the thickness of the functional insert.

[0081] The release films are not made of a thermoplastic material. They are made of a material that does not bond adhesively to the first bonding layer, the second bonding layer, the functional insert, or, if present, the third frame-like layer during lamination. These release films are made, for example, of Teflon or polyvinyl fluoride (PVF).

[0082] The third frame-shaped layer has a recess, as described above. The functional insert is positioned in this recess so that it directly abuts the first main surface of the first bonding layer or the second main surface of the second bonding layer. Because the third frame-shaped layer is positioned between two separating films, a section of the separating film adjacent to the bonding layer to which the functional insert does not directly abut is also positioned within the recess in the third frame-shaped layer. This prevents the functional insert from bonding with the third frame-shaped layer.

[0083] In the embodiment described above, the frame layer of the composite disc produced by the method preferably consists of the first frame-shaped layer. Since, according to the invention, the thickness of the frame layer is greater than the thickness of the functional insert, in this preferred embodiment, in which the frame layer consists of the first frame-shaped layer, the thickness of the first frame-shaped layer is thus greater than the thickness of the functional insert.

[0084] The placeholders are made of a material that, particularly during lamination, does not bond adhesively to either the second bonding layer or the second disc. These placeholders are made, for example, of Teflon or polyvinyl fluoride (PVF).

[0085] Optionally, the first and second pre-assemblies can preferably be subjected to an autoclave process together before the production of the second layer stack. Likewise, the third and fourth pre-assemblies can preferably be subjected to an autoclave process together before the production of the second layer stack.

[0086] In a preferred embodiment of the method according to the invention, in step b) during the filling of the optically clear adhesive in liquid form, an internal hydrostatic pressure exerted by the optically clear adhesive on the second surface of the first disk and the third surface of the second disk is counteracted by an external hydrostatic pressure exerted on the first surface of the first disk and the fourth surface of the second disk. This is preferably achieved by means of pressure cushions or a water column from a water tank. Counteracting this with an external hydrostatic pressure using a water column from a water tank is described, for example, in DE202023103995U1.

[0087] 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 for producing a laminated disc can be used. Lamination by autoclaving is carried out at an elevated pressure of approximately 10 bar to 5 bar and temperatures of 100 °C to 50 °C, preferably 20 °C to 45 °C, for a period of 1 to 4 hours, preferably 2 to 3 hours. Pressing in a calender between at least one pair of rollers is also possible. The temperature during the pressing process is, for example, 40 °C to 50 °C. Combinations of calender and autoclaving processes have proven particularly effective in practice. Alternatively, vacuum lamination can also be used.Vacuum laminators consist of one or more heated and evacuatable chambers in which glass panes are laminated within 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. The lamination of laminated glass panes has been described extensively in patent literature and is also well known to those skilled in the art from the industrial mass production of laminated glass panes, so that it need not be discussed in detail here.

[0088] In a preferred embodiment of the method according to the invention, the functional insert is an electrical insert element, in particular an electro-optical functional element with electrically controllable optical properties, in particular an SPD functional element, a functional element based on liquid crystal technology, in particular a PDLC functional element, a guest-host functional film or an electrochromic functional element, a light source or a light guide or a photovoltaic module.

[0089] The above statements relating to the composite disc according to the invention apply analogously to the inventive method for producing a composite disc. Similarly, the statements relating to the inventive method for producing a composite disc apply analogously to the composite disc according to the invention.

[0090] 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.

[0091] The invention is explained in more detail below with reference to drawings and exemplary embodiments. The drawings are schematic representations and not to scale. The drawings do not limit the invention in any way.

[0092] They show:

[0093] Fig. 1 is a top view of an embodiment of a device according to the invention.

[0094] Composite disc

[0095] Fig. 2 shows a cross-section through an embodiment of an invention.

[0096] Composite disc

[0097] Fig. 3 shows a cross-section through another embodiment of an invention.

[0098] Composite disc

[0099] Fig. 4 shows a cross-section through another embodiment of a composite disk according to the invention,

[0100] Fig. 5 shows a cross-section through another embodiment of a composite disk according to the invention,

[0101] Fig. 6 shows a cross-section through another embodiment of an invention.

[0102] Composite disc

[0103] Fig. 7 is a flowchart of a method according to the invention, Fig. 8 is a flowchart of an embodiment of step S1 of the method shown in Fig. 7,

[0104] Fig. 9 shows a cross-section through an embodiment of a first layer stack,

[0105] Fig. 10 shows a cross-section through an embodiment of a second layer stack,

[0106] Fig. 11 shows a cross-section through an embodiment of a composite,

[0107] Fig. 12 is an exploded view of the embodiment shown in Fig. 11 of a

[0108] network

[0109] Fig. 13 shows an embodiment of an arrangement consisting of a composite and a device for filling before filling,

[0110] Fig. 14 shows an embodiment of an arrangement consisting of a composite disc according to the invention and a device for filling after filling and hardening,

[0111] Fig. 15 shows another embodiment of an arrangement consisting of a composite and a device for filling before filling,

[0112] Fig. 16 shows a further embodiment of an arrangement consisting of a composite disc according to the invention and a device for filling after filling and hardening,

[0113] Fig. 17 is an enlargement of section Z from Fig. 16.

[0114] Fig. 18 shows a flowchart of another embodiment of step S1 of the method shown in Fig. 7,

[0115] Fig. 19 shows a cross-section through another embodiment of a first

[0116] Layer stack.

[0117] Fig. 1 shows a top view of an embodiment of a composite disc 100 according to the invention, and Fig. 2 shows a cross-section through an embodiment of a composite disc 100 according to the invention, corresponding to the cross-section along section line XX' of Fig. 1. As can be seen from Fig. 1 and Fig. 2, the composite disc 100 comprises a first disc 1, a second disc 2, a first bonding layer 3, a second bonding layer 4, a frame layer 5, a layer of a cured optically clear adhesive 13, and a functional insert 9.

[0118] The first disk 1 has a first surface I and a second surface II, and the second disk 2 has a third surface III and a fourth surface IV. In the embodiment shown in Figures 1 and 2, the second surface II of the first disk 1 and the third surface III of the second disk 2 face each other. Between the first disk 1 and the second disk 2 are arranged the first bonding layer 3, the second bonding layer 4, and the frame layer 5, with the first bonding layer 3 being located between the first disk 1 and the frame layer 5, and the second bonding layer 4 being located between the second disk 2 and the frame layer 5. The frame layer 5 has a cutout 6, which is bounded by the first bonding layer 3 and the second bonding layer 4 and through which a receiving space 7 is formed.The frame layer 5 has a thickness, and the functional insert 9 has a thickness, and the thickness of the frame layer 5 is greater than the thickness of the functional insert 9. The receiving space 7 consists of a first sub-area and a second sub-area immediately adjacent to the first sub-area. The functional insert 9 has a planar shape and comprises a first main surface 10 and a second main surface 11, as well as an edge surface 12 extending between them. In the embodiment shown in Fig. 2, the functional insert 9 is arranged in the first sub-area of ​​the receiving space 7 such that it directly abuts the first main surface 10 of the first bonding layer 3 and completely fills the first sub-area. As can be seen from Figs. 1 and 2, the composite disk 100 has two through-holes 8, which extend from the fourth surface IV of the second disk 2 to the second sub-area of ​​the receiving space 7.In the embodiment shown in Fig. 2, the layer of cured, optically clear adhesive 13 completely fills the second sub-area and the through-holes 8 completely. The through-holes 8 each have, for example, a diameter of 7 mm.

[0119] The first disc 1 and the second disc 2, for example, consist of soda-lime glass and each have a thickness of 2.1 mm.

[0120] The first bonding layer 3, the second bonding layer 4, and the frame layer 5 are made of polyvinyl butyral (PVB), for example. The first bonding layer 3 and the second bonding layer 4 are, for example, 0.38 mm and 0.76 mm thick, respectively.

[0121] The functional insert 9 is, for example, an electro-optical functional element, such as an SPD functional element, a PDLC functional element, or preferably a guest-host film. In the embodiment shown in Figures 1 and 2, the through-holes 8, when viewed through the composite disk 100 from the fourth surface IV, lie outside the area in which the functional insert 9 is arranged.

[0122] The cured optically clear adhesive 13, for example, is an optically clear adhesive that has been cured using UV radiation.

[0123] Fig. 3 shows a cross-section through another embodiment of a composite disc 100 according to the invention. The embodiment shown in Fig. 3 corresponds essentially to the embodiment shown in Figs. 1 and 2. The embodiment shown in Fig. 3 differs from that shown in Fig. 2 only in that, in Fig. 3, the frame layer 5 consists of a first frame-shaped layer 14 with a recess. The first frame-shaped layer 14 consists, for example, of PVB. The functional insert 9 is arranged in the recess. The recess has larger outer dimensions than the outer dimensions of the functional insert 9. Thus, in the embodiment shown in Fig. 3, the functional insert 9 does not have direct contact with the first frame-shaped layer 14.

[0124] Fig. 4 shows a cross-section through another embodiment of a composite disc 100 according to the invention. The embodiment shown in Fig. 4 corresponds essentially to the embodiment shown in Figs. 1 and 2. The embodiment shown in Fig. 4 differs from that shown in Fig. 2 only in that, in Fig. 4, the frame layer 5 consists of a first frame-shaped layer 14 with a recess and a second frame-shaped layer 15 with a recess. The first frame-shaped layer 14 is arranged directly adjacent to the first bonding layer 3, and the second frame-shaped layer 15 is arranged directly adjacent to the second bonding layer 4. The functional insert 9 is arranged in the recess of the first frame-shaped layer 14. The recess in the first frame-shaped layer 14 has larger outer dimensions than the outer dimensions of the functional insert 9.In the embodiment shown in Fig. 4, the functional insert 9 therefore has no direct contact with the first frame-shaped layer 14. The recess in the first frame-shaped layer 14 and the recess in the second frame-shaped layer 15 are aligned congruently when viewed through the composite disc 100 from the fourth surface IV. The first frame-shaped layer 14 is made, for example, of PVB. The second frame-shaped layer 15 is, for example, based on a butyl adhesive. In the embodiment shown in Fig. 4, the thickness of the first frame-shaped layer 14 corresponds to the thickness of the insert 9.

[0125] Fig. 5 shows a cross-section through another embodiment of a composite disc 100 according to the invention. The embodiment shown in Fig. 5 differs from that shown in Fig. 4 only in that the outer dimensions of the recess in the first frame-shaped layer 14 correspond to the outer dimensions of the functional insert 9. The functional insert 9 is thus arranged to fit precisely in the recess in the first frame-shaped layer 14. Consequently, the functional insert 9 has direct contact with the first frame-shaped layer 14 via its edge surface 12. In this embodiment, the recess in the first frame-shaped layer 14 is smaller, viewed perpendicularly through the composite disc 100, than the recess in the second frame-shaped layer 15 and lies entirely within the area in which the recess in the second frame-shaped layer 15 is located.

[0126] In the embodiments of a composite disc 100 according to the invention shown in Figures 2, 3, 4 and 5, the composite disc 100 has a second bonding layer 4. It is understood that the embodiments shown in Figures 2, 3, 4 and 5 can be modified such that they do not have a second bonding layer 4, and thus the frame layer 5 and the layer of a cured, optically clear adhesive 13 are arranged directly adjacent to the second disc 2.

[0127] Fig. 6 shows a cross-section through a further embodiment of a composite disc 100 according to the invention. The embodiment shown in Fig. 6 differs from that shown in Fig. 2 only in that the functional insert 9 does not directly abut the first main surface 10 of the first bonding layer 3, but directly abuts the second main surface 11 of the second bonding layer 4.

[0128] It is understood that the embodiments shown in Figures 3 and 4 can also be modified such that the functional insert 9 directly abuts the second main surface 11 of the second bonding layer 4, with the first frame-shaped layer 14 also being arranged directly adjacent to the second bonding layer 4. Figure 7 shows a flowchart of a method according to the invention for producing a composite disc 100 according to the invention with a functional insert.

[0129] In a first step S1, a composite 16 is provided, comprising a first disk 1 with a first surface I and a second surface II, a first bonding layer 3, a frame layer 5 with a cutout 6, a functional insert 9 with a planar shape, which has a first main surface 10 and a second main surface 11, as well as an intermediate edge surface 12, a second disk 2 with a third surface III and a fourth surface IV and optionally a second bonding layer 4, wherein the second surface II and the third surface III face each other, the frame layer 5 has a thickness and is arranged between the first disk 1 and the second disk 2, the first bonding layer 3 is arranged between the first disk 1 and the frame layer 5, the optional second bonding layer 4 is arranged between the frame layer 5 and the second disk 2,the cutout 6 in the frame layer 5 forms a receiving space 7, which consists of a first sub-area and a second sub-area immediately adjacent to the first sub-area, the functional insert 9 has a thickness and is arranged in the first sub-area of ​​the receiving space 7 such that it directly abuts the first main surface 10 of the first connecting layer 3 or the second main surface 11 of the optional second connecting layer 4 and completely fills the first sub-area, wherein the thickness of the frame layer 5 is greater than the thickness of the functional insert 9, and the assembly 16 has at least two through holes 8 which extend from the fourth surface IV to the second sub-area of ​​the receiving space 7.

[0130] In a subsequent second step S2, an optically clear adhesive 13 in liquid form is injected into the receiving space 7 of the composite 16 through at least one of the through-holes 8, whereby gaseous substances contained in the receiving space 7 can escape through at least one other of the through-holes 8, such that the optically clear adhesive 13 completely fills the second sub-area and at least partially fills the through-holes 8.

[0131] In a subsequent third step S3, the optically clear adhesive 13 is cured.

[0132] Fig. 8 shows a flowchart of an embodiment of step S1 of the method shown in Fig. 7. In this embodiment, step S1 comprises the following steps P1 to P7, which are carried out in the specified order: P1) Providing the first disk 1, the second disk 2, the first bonding layer 3, the second bonding layer 4, a first frame-shaped layer 14 with a recess, and the functional insert 9, wherein the second bonding layer 4 has at least two holes 18 and the second disk 2 has at least two holes 19.

[0133] P2) Producing a first stack of layers 20 comprising the first disk 1 and the second disk 2, wherein the second surface II and the third surface III face each other, with the first bonding layer 3 and the second bonding layer 4 interposed, wherein the first bonding layer 3 is positioned immediately adjacent to the first disk 1 and the second bonding layer 4 is positioned immediately adjacent to the second disk 2 such that a hole 18 in the second bonding layer 4 and a hole 19 in the second disk 2 form a common through-hole 8, wherein a separating film 17 is arranged between the first bonding layer 3 and the second bonding layer 4, and the first frame-shaped layer 14 is located between the separating film 17 and the first

[0134] bonding layer 3 or between the separating film 17 and the second

[0135] The connecting layer 4 is arranged, the functional insert 9 is arranged in the recess in the first frame-shaped layer 14, and placeholders 21 are arranged in the through holes 8.

[0136] P3) Laminating the first stack of layers 20 to firmly bond the first disk 1 to the first bonding layer 3, to firmly bond the second disk 2 to the second bonding layer 4, and to firmly bond the functional insert 9 and the first frame-shaped layer 14 to the first bonding layer 3 or the second bonding layer 4, thereby producing a first pre-composite 22 from the first disk 2, the first bonding layer 3, the first frame-shaped layer 14, and the functional insert 9, and a second pre-composite 23 from the second disk 2 and the second bonding layer 4, or a first pre-composite 22 from the first disk 2 and the first bonding layer 3, and a second pre-composite 23 from the second disk 2 and the second bonding layer 4, the first frame-shaped layer 14, and the functional insert 9.

[0137] P4) Separating the first pre-composite 22 from the second pre-composite 23 at the separating film 17 and removing the separating film 17,

[0138] P5) Producing a second stack of layers 24, comprising the first pre-composite 22 and the second pre-composite 23, wherein the second surface II and the third surface III are facing each other and optionally a second frame-shaped layer 15 with a recess is arranged between the first pre-composite 22 and the second pre-composite 23,

[0139] P6) Joining the second layer stack 24, in particular by lamination in an autoclave,

[0140] P7) Removing the placeholders 21 from the through holes 8.

[0141] Fig. 9 shows a cross-section through an embodiment of a first layer stack 20, as it is present in the manufacture of the embodiment of a composite disk 100 according to the invention shown in Fig. 5 after step P2 of the method shown in Fig. 8.

[0142] The first layer stack 20 shown in Fig. 9 comprises a first disk 1 with a first surface I and a second surface II, and a second disk 2 with a third surface III and a fourth surface IV. The second surface II and the third surface III face each other in the first layer stack 20, with a first connecting layer 3 and a second connecting layer 4 interposed between them. The first connecting layer 3 is positioned immediately adjacent to the first disk 1, and the second connecting layer 4 is positioned immediately adjacent to the second disk 2. The second disk 2 has two holes 19, and the second connecting layer 4 has two holes 18. The second connecting layer 4 and the second disk 2 are positioned such that each hole 18 in the second connecting layer 4 and each hole 19 in the second disk 2 form a common through-hole 8.In the first layer stack 20, a separating film 17 is arranged between the first bonding layer 3 and the second bonding layer 4, and a first frame-shaped layer 14 with a recess is arranged between the separating film 17 and the first bonding layer 3. A functional insert 9 is arranged in the recess in the first frame-shaped layer 14. The functional insert 9 has a planar shape and comprises a first main surface 10 and a second main surface 11, as well as an edge surface 12 extending between them. The recess in the first frame-shaped layer 14 has the same external dimensions as the functional insert 9, so that the functional insert 9 fits precisely in the recess and has direct contact with the first frame-shaped layer 14 via its edge surface 12. Furthermore, placeholders 21 are arranged in the through holes 8.The first disc 1 and the second disc 2, for example, consist of soda-lime glass and each have a thickness of 2.1 mm.

[0143] The first bonding layer 3 and the second bonding layer 4 are made, for example, of polyvinyl butyral (PVB). The first bonding layer 3 and the second bonding layer 4 are, for example, each 0.38 mm or 0.76 mm thick. The functional insert 9 is, for example, an electro-optical functional element, such as an SPD functional element, a PDLC functional element, or preferably a guest-host film. The separating film 17 is made, for example, of Teflon or PVF and is, for example, 25 µm or 2 mm thick and, in the embodiment shown in Fig. 9, projects beyond the side edges of the first disk 1 and the second disk 2 by, for example, 1 cm. The placeholders 21 are made, for example, of Teflon. The through-holes 8 each have, for example, a diameter of 7 mm. The first frame-shaped layer 14 is made, for example, of PVB.

[0144] In the embodiment shown in Fig. 9, the through holes 8, when viewed through the first layer stack 20 from the fourth surface IV, lie outside the area in which the functional insert 9 is arranged.

[0145] Fig. 10 shows a cross-section through an embodiment of a second layer stack 24, as it is present in the manufacture of the embodiment of a composite disk according to the invention shown in Fig. 5 after step P5.

[0146] The second layer stack 24 shown in Fig. 10 comprises a first pre-assembly 22 consisting of a first disk 2, a first bonding layer 3, a first frame-shaped layer 14, and a functional insert 9, and a second pre-assembly 23 consisting of a second disk 2 and a second bonding layer 4. The first disk 1 has a first surface I and a second surface II, and the second disk 2 has a third surface III and a fourth surface IV. The second surface II and the third surface III face each other in the second layer stack 24, with the first bonding layer 3 and the second bonding layer 4 interposed, the first bonding layer 3 being positioned directly adjacent to the first disk 1 and the second bonding layer 4 being positioned directly adjacent to the second disk 2.The second disk 2 has two holes 19, and the second connecting layer 4 has two holes 18. The second connecting layer 4 and the second disk 2 are positioned such that one hole 18 in the second connecting layer 4 and one hole 19 in the second disk 2 form a common through-hole 8. In the second layer stack 24, a first frame-shaped layer 14 with a recess and a second frame-shaped layer 15 with a recess are arranged between the first connecting layer 3 and the second connecting layer 4, and a functional insert 9 is arranged in the recess in the first frame-shaped layer 14. The recess in the first frame-shaped layer 14 has the same outer dimensions as the functional insert 9, so that the functional insert 9 fits precisely in the recess and has direct contact with the first frame-shaped layer 14 with its edge surface 12.The recess in the first frame-shaped layer 14, viewed perpendicularly through the second layer stack 24, is smaller than the recess in the second frame-shaped layer 15 and lies entirely within the area where the recess in the second frame-shaped layer 15 is located. The recesses in the first frame-shaped layer 14 and the second frame-shaped layer 15 are bounded by the first connecting film 3 and the second connecting film 4, respectively, creating a receiving space 7 consisting of a first sub-area and a second sub-area. The functional insert 9 is located in the first sub-area. Placeholders 21 are arranged in the through-holes 8.

[0147] The first disc 1 and the second disc 2, for example, consist of soda-lime glass and each have a thickness of 2.1 mm.

[0148] The first bonding layer 3 and the second bonding layer 4 are made, for example, of polyvinyl butyral (PVB). The first bonding layer 3 and the second bonding layer 4 are, for example, each 0.38 mm or 0.76 mm thick. The functional insert 9 is, for example, an electro-optical functional element, such as an SPD functional element, a PDLC functional element, or preferably a guest-host film. The placeholders 21 are made, for example, of Teflon. The through-holes 8 each have, for example, a diameter of 7 mm. The first frame-shaped layer 14 is made, for example, of PVB. The second frame-shaped layer 15 is, for example, based on a butyl adhesive. In the embodiment shown in Fig. 10, when looking through the second layer stack 24 from the fourth surface IV, the through-holes 8 lie outside the area in which the functional insert 9 is arranged.

[0149] Fig. 11 shows a cross-section through an embodiment of a composite 16 and Fig. 12 shows an exploded view of the embodiment of a composite 16 shown in Fig. 11, as it is present in the manufacture of the embodiment of a composite disk according to the invention shown in Fig. 5 after step S1 or step P7.

[0150] The composite 16 shown in Figs. 11 and 12 differs from the second layer stack 24 shown in Fig. 10 only in that the layer stack was joined in particular by lamination in an autoclave and that no placeholders 21 are included in the through holes 8.

[0151] Fig. 13 shows an embodiment of an arrangement consisting of a composite 16 and a filling device prior to filling, and Fig. 14 shows a corresponding arrangement consisting of the resulting composite disc 100 according to the invention after filling with and curing of the optically clear adhesive 13, wherein the composite 16 is constructed as shown in Figs. 11 and 12 and the composite disc 100 is constructed as shown in Fig. 5. Therefore, only the features beyond those shown in Figs. 5, 11, and 12 will be discussed below.

[0152] In the embodiment of an arrangement shown in Fig. 13, a connecting line 30, extending from a metering unit (not shown in Fig. 13) for liquid, optically clear adhesive 13, is attached to the fourth surface IV of the second disk 2 in the area of ​​a through-hole 8 by means of a filling port 26 and a seal 28. As can be seen in Fig. 13, a portion of the connecting line 30 projects into the through-hole 8. Additionally, a line 31 is attached to the fourth surface IV of the second disk 2 in the area of ​​another through-hole 8 by means of a vent port 27 and a seal 28. A portion of the line 31 projects into this second through-hole 8. The diameter of the connecting line 30 and the line 31 is adapted to the diameter of the respective through-hole 8. The filling port 26 and the vent port 27 are each supported by a support device 29.Two support devices 29 are also arranged on the first surface I of the first pane 1 to prevent slippage of the composite 16 and / or glass breakage during the filling process with the optically clear liquid adhesive 13. The support devices 29 on the first surface I of the first pane 1 are arranged, when viewed perpendicularly through the composite 16 or in orthogonal projection through the composite 16, overlapping the filling port 26 and the venting port 27, respectively.

[0153] In the embodiment of an arrangement shown in Fig. 14, the connecting line 30, the filling port 26, the line 31, the vent port 27, the seals 28 and the support devices 29 have been removed from the composite disc 100 and are thus arranged at a distance from the composite disc 100.

[0154] The connecting line 30 and the line 30 are made of, for example, plastic, aluminum, or stainless steel. The support devices 29 are made of aluminum or stainless steel. The seals 28 are, for example, rubber seals.

[0155] Fig. 15 shows a further embodiment of an arrangement consisting of a composite 16 and a device for filling before filling, and Fig. 16 shows a corresponding arrangement of the resulting composite disc 100 according to the invention after filling with and curing of the optically clear adhesive 13. Fig. 17 shows an enlargement of the section Z from Fig. 16. The arrangements shown in Figs. 15 and 16 largely correspond to the arrangements shown in Figs. 13 and 14, so that only the distinguishing features will be discussed below.

[0156] The embodiment of an arrangement shown in Fig. 15 differs from the embodiment shown in Fig. 13 in that no seals 28 are arranged between the filling port 26, the vent port 27, and the fourth surface IV of the second disk 2, and between the vent port 27 and the fourth surface IV of the second disk 2; instead, the seal is provided by means of a press fit. However, a gripper with a cutting blade 32 is arranged between the support device 29 of the filling port 26 and the second disk 2, and between the support device 29 of the vent port 27 and the second disk 2. These grippers with cutting blades 32 are suitable for cutting the connecting line 30 and the line 31, respectively.

[0157] In the embodiment of an arrangement shown in Fig. 16, the filling connection

[0158] 26, the vent connection 27, the seals 28, and the support devices 29 have been removed from the composite disk 100 and are thus arranged at a distance from the composite disk 100. The connecting line 30 and the line 31 have been severed by the cutting blades of the grippers with cutting blades 32 in the area of ​​the fourth surface IV of the second disk 2 in the arrangement shown in Fig. 16. The part of the connecting line 30 and the part of the line 31 which is arranged in the through holes 8 in Fig. 15 has remained in the through holes 8, with the connecting line 30 and the line 31 each being pressed together in the area of ​​the fourth surface IV of the second disk 2, as also shown in the enlarged view of the section Z in Fig. 17. The remaining part of the connecting line 30 and the remaining part of the line 31 have been removed from the composite disc 100 and are thus arranged at a distance from the composite disc 100.

[0159] Fig. 18 shows a flowchart of another embodiment of step S1 of the method shown in Fig. 7. In this embodiment, step S1 comprises the subsequent steps P1 to P7, which are carried out in the specified order:

[0160] P1) Providing the first disk 1, the second disk 2, the first connecting layer 3, the second connecting layer 4 and the functional insert 9 with a planar shape and a first main surface 10 and a second main surface 11 and an intermediate edge surface 12, wherein the second connecting layer 4 has at least two holes 18 and the second disk 2 has at least two holes 19,

[0161] P2) Producing a first stack of layers 20 comprising the first disk 1 and the second disk 2, wherein the second surface II and the third surface III face each other with the first bonding layer 3 and the second bonding layer 4 interposed, wherein the first bonding layer 3 is positioned immediately adjacent to the first disk 1 and the second bonding layer 4 is positioned immediately adjacent to the second disk 2 such that a hole 18 in the second bonding layer 4 and a hole 19 in the second disk 2 form a common through-hole 8, wherein two separating films 17 are arranged between the first bonding layer 3 and the second bonding layer 4, a third frame-shaped layer 25 with a recess between the two separating films 17 is arranged and the functional insert 9 is arranged in the recess in the third frame-shaped layer 25 such thatthat it directly abuts the first main surface 10 of the first connecting layer 3 or the second main surface 11 of the second connecting layer 4, and placeholders 21 are arranged in the through holes 8,

[0162] P3) Laminating the first stack of layers 20 to firmly bond the first disk 1 to the first bonding layer 3, to firmly bond the second disk 2 to the second bonding layer 4 and to firmly bond the functional insert 9 to the first bonding layer 3 or the second bonding layer 4, thereby producing a third pre-composite consisting of the first disk 2, the first bonding layer 3 and the functional insert 9 and a fourth pre-composite consisting of the second disk 2 and the second bonding layer 4 or a third pre-composite consisting of the first disk 2 and the first bonding layer 3 and a fourth pre-composite consisting of the second disk 2 and the second bonding layer 4 and the functional insert 9,

[0163] P4) Separating the third pre-composite from the fourth pre-composite at the separating films 17 and removing the separating films 17 and the third frame-shaped layer 25,

[0164] P5) Producing a second stack of layers 24, comprising the third pre-composite and the fourth pre-composite, wherein the second surface II and the third surface III are facing each other and a frame layer 5 with a cutout 6 is arranged between the third pre-composite and the fourth pre-composite such that the functional insert 9 is arranged in the cutout 6,

[0165] P6) Joining the second layer stack 24, in particular by lamination in an autoclave,

[0166] P7) Removing the placeholders 21 from the through holes 8.

[0167] Fig. 19 shows a cross-section through an embodiment of a first layer stack 20, as it is present in the manufacture of the embodiment of a composite disk 100 according to the invention shown in Fig. 2, 3, 4 or 5 after step P2 of the method shown in Fig. 18.

[0168] The first layer stack 20 shown in Fig. 19 comprises a first disk 1 with a first surface I and a second surface II, and a second disk 2 with a third surface III and a fourth surface IV, wherein the second surface II and the third surface III face each other. A first connecting layer 3 and a second connecting layer 4 are arranged between the first disk 1 and the second disk 2. The second disk 2 has two holes 19, and the second connecting layer 4 has two holes 18. The first connecting layer 3 is positioned immediately adjacent to the first disk 1, and the second connecting layer 4 is positioned immediately adjacent to the second disk 2 such that each hole 18 in the second connecting layer 4 and each hole 19 in the second disk 2 form a common through-hole 8.Two separating films 17 are arranged between the first bonding layer 3 and the second bonding layer 4. A third frame-shaped layer 25 with a recess is arranged between the two separating films 17, and a functional insert 9 is arranged in the recess in the third frame-shaped layer 25. The functional insert 9 has a planar shape and comprises a first main surface 10 and a second main surface 11, as well as an intermediate edge surface 12. The insert 9 is arranged in the recess in the third frame-shaped layer 25 such that it directly abuts the first main surface 10 of the first bonding layer 3. Placeholders 21 are arranged in the through-holes 8. The third frame-shaped layer 25 is made, for example, of PVB. Alternatively, the third frame-shaped layer 25 could also be made, for example, of Teflon, and in this case, the arrangement shown in Fig.19 The separating film 17 arranged between the third frame-shaped layer 25 and the second connecting layer 4 can also be omitted, or the third frame-shaped layer 25 can be arranged between the separating film 17 and the second connecting layer 4.

[0169] The first disc 1 and the second disc 2, for example, consist of soda-lime glass and each have a thickness of 2.1 mm.

[0170] The first bonding layer 3 and the second bonding layer 4 are made, for example, of polyvinyl butyral (PVB). The first bonding layer 3 and the second bonding layer 4 are, for example, each 0.38 mm or 0.76 mm thick. The functional insert 9 is, for example, an electro-optical functional element, such as an SPD functional element, a PDLC functional element, or preferably a guest-host film. The separating films 17 are made, for example, of Teflon and are, for example, 25 µm or 2 mm thick and, in the embodiment shown in Fig. 19, project beyond the side edges of the first disk 1 and the second disk 2. The placeholders 21 are made, for example, of Teflon. The through-holes 8 each have, for example, a diameter of 7 mm.

[0171] In the embodiment shown in Fig. 19, the through holes 8, when viewed through the first layer stack 20 from the fourth surface IV, lie outside the area in which the functional insert 9 is arranged. Reference numeral list:

[0172] 100 composite disc

[0173] 1 first disc

[0174] 2 second disc

[0175] 3 first bonding layer

[0176] 4 second bonding layer

[0177] 5 frame layer

[0178] 6 Excerpt

[0179] 7 Recording room

[0180] 8 through holes

[0181] 9 functional insert

[0182] 10 first main area

[0183] 11 second main area

[0184] 12 edge surfaces

[0185] 13 optically clear adhesive

[0186] 14 first frame-shaped layer

[0187] 15 second frame-shaped layer

[0188] 16 network

[0189] 17 Separating film

[0190] 18 holes (in the second bonding layer)

[0191] 19 holes (in the second disc)

[0192] 20 first layer stack

[0193] 21 placeholders

[0194] 22 first pre-assembly

[0195] 23 second pre-assembly

[0196] 24 second layer stacks

[0197] 25 third frame-shaped layer

[0198] 26 Filling port

[0199] 27 Vent connection

[0200] 28 Seal

[0201] 29 Support device

[0202] 30 connecting cable

[0203] 31 Line 32 Gripper with cutting blade

[0204] I first surface

[0205] II second surface III third surface

[0206] IV fourth surface

[0207] XX' Intersection line

[0208] Z-shaped neckline

Claims

Patent claims 1. Composite disc (100), comprising at least - a first disk (1) with a first surface (I) and a second surface (II) and a second disk (2) with a third surface (III) and a fourth surface (IV), wherein the second surface (II) and the third surface (III) are facing each other, - a first bonding layer (3), a frame layer (5) with a thickness and optionally a second bonding layer (4) arranged between the first disk (1) and the second disk (2), wherein the first bonding layer (3) is arranged between the first disk (1) and the frame layer (5), the optional second bonding layer (4) is arranged between the frame layer (5) and the second disk (2), the frame layer (5) has a cutout (6) through which a receiving space (7) is formed, consisting of a first sub-area and a second sub-area immediately adjacent to the first sub-area, and the composite disk (100) has at least two through holes (8) extending from the fourth surface (IV) to the second sub-area of ​​the receiving space (7), - a functional insert (9) with a planar shape and thickness, which has a first main surface (10) and a second main surface (11), as well as an intermediate edge surface (12), wherein the functional insert (9) is arranged in the first sub-area of ​​the receiving space (7) such that it directly abuts the first main surface (10) of the first connecting layer (3) or the second main surface (11) of the optional second connecting layer (4) and completely fills the first sub-area, wherein the thickness of the frame layer (5) is greater than the thickness of the functional insert (9), and - a layer of a cured optically clear adhesive (13) which completely fills the second sub-area and at least partially fills the through-holes (8).

2. Composite disc (100) according to claim 1, wherein the through holes (8) are located outside the area in which the functional insert (9) is arranged when looking through the composite disc (100) from the fourth surface (IV).

3. Composite disc (100) according to claim 1 or 2, wherein the functional insert (9) is an electro-optical functional element with electrically controllable optical properties, in particular an SPD functional element, a functional element based on liquid crystal technology, in particular a PDLC functional element, a guest-host functional film or an electrochromic functional element, a light source or a light guide or a photovoltaic module.

4. Composite disc (100) according to one of claims 1 to 3, wherein the frame layer (5) consists of a first frame-shaped layer (14) with a recess and the functional insert (9) is arranged in the recess in the first frame-shaped layer (14) such that it has no direct contact with the first frame-shaped layer (14) with the edge surface (12).

5. Composite disc (100) according to one of claims 1 to 3, wherein the frame layer (5) consists of a first frame-shaped layer (14) with a recess and a second frame-shaped layer (15) with a recess, which are arranged one above the other in a planar fashion and wherein the functional insert (9) is arranged in the recess in the first frame-shaped layer (14) such that its edge surface (12) has no direct contact with the first frame-shaped layer (14) and no direct contact with the second frame-shaped layer (15).

6. Composite disc (100) according to one of claims 1 to 3, wherein the frame layer (5) consists of a first frame-shaped layer (14) with a recess and a second frame-shaped layer (15) with a recess, which are arranged over one another and wherein the functional insert (9) is arranged in the recess in the first frame-shaped layer (14) such that its edge surface (12) has direct contact with the first frame-shaped layer (14) and no direct contact with the second frame-shaped layer (15).

7. Composite disc (100) according to claim 5 or 6, wherein, in a perpendicular view through the composite disc (100), the thickness of the first frame-shaped layer (14) is equal to the thickness of the functional insert (9).

8. Composite disc (100) according to one of claims 1 to 7, wherein the bonding layer of the first bonding layer (3) and the second bonding layer (4) to which the functional insert (9) directly abuts has a UV blocker.

9. Composite disc (100) according to one of claims 1 to 8, wherein the functional insert (9) is directly adjacent to the first main surface (10) of the first bonding layer (3).

10. Method for producing a composite disc (100) according to any one of claims 1 to 9, comprising at least the following steps: a) providing a composite (16) comprising a first disc (1) with a first surface (I) and a second surface (II), a first bonding layer (3), a frame layer (5) with a cutout (6), a functional insert (9) with a planar shape, which has a first main surface (10) and a second main surface (11) as well as an intermediate edge surface (12), a second disc (2) with a third surface (III) and a fourth surface (IV) and optionally a second bonding layer (4), wherein the second surface (II) and the third surface (III) face each other, the frame layer (5) has a thickness and is arranged between the first disc (1) and the second disc (2), the first bonding layer (3) is arranged between the first disc (1) and the frame layer (5),the optional second connecting layer (4) is arranged between the frame layer (5) and the second disk (2), the cutout (6) in the frame layer (5) forms a receiving space (7) consisting of a first sub-area and a second sub-area immediately adjacent to the first sub-area, the functional insert (9) has a thickness and is arranged in the first sub-area of ​​the receiving space (7) such that it directly abuts the first main surface (10) of the first connecting layer (3) or the second main surface (11) of the optional second connecting layer (4) and completely fills the first sub-area, wherein the thickness of the frame layer (5) is greater than the thickness of the functional insert (9), and the assembly (16) has at least two through holes (8) extending from the fourth surface (IV) to the second sub-area of ​​the receiving space (7),b) Pouring an optically clear adhesive (13) in liquid form into the receiving chamber (7) of the composite (16) through at least one of the through-holes (8), wherein gaseous substances contained in the receiving chamber (7) can escape through at least one other of the through-holes (8), such that the optically clear adhesive (13) completely fills the second sub-area and at least partially fills the through-holes (8), c) Curing of the optically clear adhesive (13).

11. Method according to claim 10, wherein step a) comprises the following steps: a1) providing the first disk (1), the second disk (2), the first bonding layer (3), the second bonding layer (4), a first frame-shaped layer (14) with a recess, and the functional insert (9), wherein the second bonding layer (4) has at least two holes (18) and the second disk (2) has at least two holes (19), a2) producing a first stack of layers (20) comprising the first disk (1) and the second disk (2), wherein the second surface (II) and the third surface (III) are facing each other with the first bonding layer (3) and the second bonding layer (4) interposed, wherein the first bonding layer (3) is positioned immediately adjacent to the first disk (1) and the second bonding layer (4) is positioned immediately adjacent to the second disk (2),that a hole (18) in the second connecting layer (4) and a hole (19) in the second disk (2) each form a common through-hole (8), wherein a separating film (17) is arranged between the first connecting layer (3) and the second connecting layer (4), the first frame-shaped layer (14) is arranged between the separating film (17) and the first connecting layer (3) or between the separating film (17) and the second connecting layer (4), the functional insert (9) is arranged in the recess in the first frame-shaped layer (14), and placeholders (21) are arranged in the through-holes (8),a) Laminating the first stack of layers (20) to firmly connect the first disk (1) to the first bonding layer (3) and to firmly connect the second disk (2) to the second bonding layer (4) and to firmly connect the functional insert (9) and the first frame-shaped layer (14) to the first bonding layer (3) or the second bonding layer (4), thereby forming a first pre-composite (22) of the first disk (2), the first bonding layer (3), the first frame-shaped layer (14) and the functional insert (9) and a second pre-composite (23) of the second disk (2) and the second bonding layer (4) or a first pre-composite (22) of the first disk (2) and the first, a bonding layer (3) and a second pre-composite (23) is produced from the second disk (2) and the second bonding layer (4), the first frame-shaped layer (14) and the functional insert (9), a4) separating the first pre-composite (22) from the second pre-composite (23) at the separating film (17) and removing the separating film (17), a5) producing a second stack of layers (24) comprising the first pre-composite (22) and the second pre-composite (23), wherein the second surface (II) and the third surface (III) are facing each other and optionally a second frame-shaped layer (15) with a recess between the first pre-composite (22) and the second pre-composite (23) is arranged, a6) joining the second stack of layers (24), in particular by lamination in an autoclave, a7) removing the placeholders (21) from the through holes (8).

12. The method of claim 10, wherein step a) comprises the following steps: a1) providing the first disk (1), the second disk (2), the first bonding layer (3), the second bonding layer (4), and the functional insert (9), wherein the second bonding layer (4) has at least two holes (18) and the second disk (2) has at least two holes (19); a2) producing a first stack of layers (20) comprising the first disk (1) and the second disk (2), wherein the second surface (II) and the third surface (III) are facing each other with the first bonding layer (3) and the second bonding layer (4) interposed, wherein the first bonding layer (3) is positioned immediately adjacent to the first disk (1) and the second bonding layer (4) is positioned immediately adjacent to the second disk (2) such thatthat a hole (18) in the second connecting layer (4) and a hole (19) in the second disk (2) each form a common through-hole (8), wherein two separating films (17) are arranged between the first connecting layer (3) and the second connecting layer (4), a third frame-shaped layer (25) with a recess is arranged between the two separating films (17), and the functional insert (9) is arranged in the recess in the third frame-shaped layer (25) such that it is aligned with the first main surface (10) of the first connecting layer (3) or with the second main surface (11) of the second, a3) bonding layer (4) directly abuts, and placeholders (21) are arranged in the through holes (8), a3) laminating the first layer stack (20) to firmly bond the first disk (1) to the first bonding layer (3), to firmly bond the second disk (2) to the second bonding layer (4) and to firmly bond the functional insert (9) to the first bonding layer (3) or the second bonding layer (4), thereby producing a third pre-composite of the first disk (2), the first bonding layer (3) and the functional insert (9) and a fourth pre-composite of the second disk (2) and the second bonding layer (4) or a third pre-composite of the first disk (2) and the first bonding layer (3) and a fourth pre-composite of the second disk (2) and the second bonding layer (4) and the functional insert (9),a4) Separating the third pre-composite from the fourth pre-composite at the separating films (17) and removing the separating films (17) and the third frame-shaped layer (25), a5) Producing a second layer stack (24) comprising the third pre-composite and the fourth pre-composite, wherein the second surface (II) and the third surface (III) face each other and a frame layer (5) with a cutout (6) is arranged between the third pre-composite and the fourth pre-composite such that the functional insert (9) is arranged in the cutout (6), a6) Joining the second layer stack (24), in particular by lamination in an autoclave, a7) Removing the placeholders (21) from the through holes (8).

13. Method according to one of claims 10 to 12, wherein in step b) when filling the optically clear adhesive (13) in liquid form, an internal hydrostatic pressure exerted by the optically clear adhesive (13) on the second surface (II) of the first disk (1) and the third surface (III) of the second disk (2) is counteracted by an external hydrostatic pressure exerted from the outside, in particular by means of pressure cushions or a water column of a water tank, on the first surface (I) of the first disk (1) and the fourth surface (IV) of the second disk (2).

14. Method according to any one of claims 10 to 13, wherein the functional insert (9) is an electro-optical functional element with electrically controllable optical properties, in particular an SPD functional element, a functional element based on liquid crystal technology, in particular a PDLC functional element, a guest-host functional film or an electrochromic functional element, a light source or an optical fiber or a photovoltaic module.

15. Use of a composite disk (100) according to any one of claims 1 to 9 on Buildings or means of transport for traffic on land, in the air or on water, in particular in motor vehicles, for example as windshield, rear window, side window and / or roof window.

Images