Transparent Hybrid Composite Coating Without Plastic Surface Damage
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Solution Overview
Problem
Existing methods for manufacturing coated transparent lightweight composites face challenges such as susceptibility of plastic panes to scratches and dents during deposition, high production costs due to yield loss of thin glass panes, and the need for high-temperature bonding processes that can damage plastic materials.
Innovation Solution
A new manufacturing sequence involving surface treatment of individual plastic and glass panes, followed by bonding them together and then applying a solar-control coating on the plastic surface, which is protected by the glass side during deposition, and optionally using a hard coating to enhance adhesion and scratch resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If coating is applied to plastic panes before bonding, then the plastic surface is protected, but the plastic becomes susceptible to scratches and dents from conveyor rollers during deposition
Solution Approach 1:
The patent inverts the conventional sequence by bonding the plastic and glass panes first to form a composite, then applying the coating. This reversal protects the plastic from mechanical damage during coating deposition, as the glass pane acts as a protective substrate during the process.
Solution Approach 2:
The patent performs the bonding action before the coating deposition, preparing the composite structure in advance. This preliminary bonding creates a robust assembly that can withstand the coating process without damaging the plastic surface.
2Weight of moving object
If thin glass panes are used to reduce weight, then the composite becomes lighter, but production costs increase due to yield loss from breakage
Solution Approach 1:
The patent bonds the thin glass pane to the plastic pane before the coating process, creating a protected composite structure. This preliminary bonding prevents breakage during subsequent handling and coating operations, reducing yield loss and production costs while maintaining the weight benefits of thin glass.
3Strength
If high-temperature bonding is used to bond glass and plastic, then strong bonding is achieved, but the plastic material is damaged due to its low glass transition temperature
Solution Approach 1:
The patent changes the temperature parameter by using low-temperature bonding methods suitable for plastics with low glass transition temperatures. This allows achieving adequate bonding strength without exposing the plastic to damaging high temperatures that would cause deformation or degradation.
4Manufacturing precision
If conventional coating sequence is used (coating plastic first), then coating adhesion is achieved, but the plastic surface is damaged during the deposition process
Solution Approach 1:
The patent inverts the conventional sequence by bonding the plastic to glass first, then applying the coating to the glass surface. This ensures the plastic surface never contacts the conveyor rollers or coating equipment, eliminating scratches and dents while maintaining coating adhesion through proper surface preparation of the glass.
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
This method reduces the risk of scratches and dents on plastic surfaces, lowers production costs by minimizing yield loss, and ensures effective bonding without high-temperature stress, resulting in a durable and cost-effective coated hybrid composite.
Implementation Method 1
reflect or absorb a portion of infrared (IR) light
Implementation Method 2
reflect or absorb a portion of infrared (IR) light
Implementation Method 3
surface treatment of individual plastic and glass panes
Data Source
AI summary
The present disclosure provides a method of making a transparent lightweight coated hybrid composite (HyC) and, particularly, to a hybrid composite coated with a thermal-insulation solar-control coating. In particular, there is disclosed the following sequence of manufacturing steps for making a coated HyC: 1) providing an individual rigid plastic pane and an individual thin glass pane; 2) preparing surface of each pane using at least one of the following methods: washing, plasma treatment, chemical activation; 3) In case of a PC pane, bonding the treated surfaces of the plastic and glass panes together by means of lamination using a thermoplastic interlayer, such as PVB, EVA, or TPU. In case of PMMA, PET, or another acrylic having a low GTP, bonding the treated surfaces of the plastic and glass panes together by means of gluing with an OCA, such as LOCA.