Composite Pane Lamination With Display Film Venting Structure
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Solution Overview
Problem
The production of composite panes with display films faces challenges in ensuring ventilation to prevent air pockets and maintain optical quality, particularly with thin thermoplastic composite films that have poor ventilation properties and are prone to air inclusions, which degrade image quality.
Innovation Solution
A method involving structuring the first thermoplastic composite film with a roughened surface and using a thicker, more plasticized second thermoplastic composite film to ensure good ventilation and mechanical stability, allowing for the creation of a composite pane with improved optical quality and simplified handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thin thermoplastic composite films are used, then image quality is improved, but ventilation is poor causing air pockets
Solution Approach 1:
The patent applies different plasticizer contents to different film layers: the first thermoplastic composite film (adjacent to display film) has ≤10 wt.% plasticizer for low air inclusion, while the second film has ≥15 wt.% plasticizer for improved ventilation and flowability during lamination. This local differentiation resolves the contradiction between image quality and ventilation.
2Manufacturing precision
If thin thermoplastic composite films are used, then image quality is improved, but mechanical stability is poor
Solution Approach 1:
The patent creates a composite structure with two different thermoplastic composite films having distinct plasticizer contents. The first film (≤10 wt.% plasticizer) provides mechanical stability and low air inclusion, while the second film (≥15 wt.% plasticizer) provides flowability during lamination. This composite approach resolves the contradiction between image quality and mechanical stability.
3Ease of operation
If higher plasticizer content is used, then flowability is improved, but air inclusion increases
Solution Approach 1:
The patent applies different plasticizer contents to different film layers: the first thermoplastic composite film (adjacent to display film) has ≤10 wt.% plasticizer for low air inclusion, while the second film has ≥15 wt.% plasticizer for improved ventilation and flowability during lamination. This local differentiation resolves the contradiction between image quality and ventilation.
4Manufacturing precision
If thin thermoplastic composite films are used, then image quality is improved, but handling is difficult
Solution Approach 1:
The patent creates a composite structure with two different thermoplastic composite films having distinct plasticizer contents. The first film (≤10 wt.% plasticizer) provides mechanical stability and low air inclusion, while the second film (≥15 wt.% plasticizer) provides flowability during lamination. This composite approach resolves the contradiction between image quality and mechanical stability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively prevents air pockets and enhances image quality by ensuring proper ventilation and mechanical stability, allowing for the use of thin thermoplastic composite films without compromising image clarity, while the thicker film with higher plasticizer content provides necessary stability and flowability during lamination.
Implementation Method 1
a first thermoplastic composite film is structured on at least one first surface by heating and applying pressure
Implementation Method 2
The layer stack comprising at least the first thermoplastic composite film, display film and second thermoplastic composite film is then combined to form a pre-composite by heating and applying pressure
Implementation Method 3
The layer stack comprising the first pane, pre-composite and second pane in this order is combined to form a composite pane by autoclaving
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3
AI summary
The invention relates to a method for producing a composite pane (100) having a display film (5), in which method a) at least one first thermoplastic composite film (3) is structured by heating and applying pressure to at least one first surface (3a), b) a layer stack is produced from the at least one first thermoplastic composite film (3), a display film (5) and a second thermoplastic composite film (4), which films are arranged one above the other in a planar manner in this order, wherein the structured first surface (3a) of the first thermoplastic composite film (3) is arranged immediately adjacently to the display film (5), c) the layer stack composed of the first thermoplastic composite film (3), the display film (5) and the second thermoplastic composite film (4) is connected, by heating and applying pressure, to form a precomposite (6), d) the precomposite (6) is placed onto a first pane (1) or a second pane (2) and is covered by a second pane (2) or a first pane (1), and e) the layer stack composed of the first pane (1), the precomposite (6) and the second pane (2), in this order, is connected by autoclaving to form a composite pane (100), wherein the first thermoplastic composite film (3) has a thickness of 25 µm to 100 µm and a plasticiser content of less than or equal to 10 wt.%, and the second thermoplastic composite film (4) has a thickness of at least 0.3 mm and a plasticiser content of greater than or equal to 15 wt.%.