Infrared-Reflecting Coating Protection in Composite Pane Production

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for producing composite panes with infrared-reflecting coatings on carrier films face challenges in protecting the coatings from damage and corrosion, particularly during the cutting back of the carrier film's edge area, which can lead to product defects due to exposure to moisture and rough surfaces.

Innovation Solution

A method involving the creation of a bilayer consisting of a carrier film with an infrared-reflective coating and a laminating film, which is then connected under pressure and rolled, allowing for the coating to be protected and easily processed, with the carrier film being cut back in the edge area before further lamination, ensuring the coating is fully covered by laminating films and thus shielded from environmental influences.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the carrier film is trimmed back at the edge to prevent corrosion, then the coating is protected from environmental influences, but the handling becomes more difficult and the risk of damage increases

Engineering Contradiction:

Improvecorrosion protectionVSAvoidhandling

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The edge of the infrared-reflecting coating is electrically insulated beforehand (e.g., by applying a protective coating or creating a non-conductive barrier) before the trimming process. This preliminary protection measure ensures that when the carrier film is later trimmed back, the coating edges are already protected from moisture and environmental corrosion, resolving the contradiction between achieving corrosion protection and maintaining ease of handling during subsequent processing steps.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the carrier film is trimmed back to protect the coating edge, then corrosion is prevented, but the production process becomes more complex

Engineering Contradiction:

Improvecorrosion protectionVSAvoidproduction process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The electrical insulation of the coating edge and the trimming of the carrier film are combined into a single integrated process step. By applying the protective insulation measure during the same operation when the carrier film edge is being trimmed, rather than as separate sequential steps, the production process complexity is minimized while still achieving both the corrosion protection and the geometric modification in one efficient operation.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If the coating is exposed during handling, then the production process is simpler, but the coating is susceptible to corrosion and scratches

Engineering Contradiction:

Improveproduction processVSAvoidcorrosion and scratches

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

A protective layer or coating is applied to the infrared-reflecting coating surface beforehand, creating a cushioning barrier that protects against scratches and corrosion during subsequent handling and processing. This prior protective measure allows the coating to remain exposed and accessible for manufacturing operations while simultaneously providing the necessary protection against harmful factors, thus resolving the contradiction between ease of manufacture and protection from damage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 effectively prevents damage and corrosion to the infrared-reflecting coating, reducing the occurrence of defects in the final composite pane by ensuring the coating is protected throughout the production process, enhancing product quality and handling safety.

Implementation Method 1

the carrier film and the first laminating film are bonded to form a bilayer under pressure at a temperature of 45°C to 65°C

Methodology Applied

Scientific EffectThermal bonding: Heat Treatment

Implementation Method 2

infrared-reflective properties, thus reducing the heating of the vehicle interior

Methodology Applied

Scientific EffectInfrared reflection: Reflection

Implementation Method 3

good electrical conductivity, allowing them to be heated so that the windshield can be kept free of ice and condensation

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP3365174B1Method for producing a composite pane having an infrared-reflecting coating on a carrier film

Publication Date: 2023.10.25 SAINT GOBAIN SEKURIT FRANCE

Figure 1a~1b
Figure 2a~2b
Figure 3

AI summary

The invention relates to a method for producing a composite pane (1), wherein a) a carrier film (5) having an electrically conductive coating (6) is provided, b) a first laminating film (4.1) is laid onto the electrically conductive coating (6) of the carrier film (5), c) the carrier film (5) and the first laminating film (4.1) are joined in order to form a bilayer (7), d) the bilayer (7) is arranged on an outer pane (2) in such a way that the first laminating film (4.1) lies on the outer pane (2) in a planar manner, e) a second laminating film (4.2) is arranged on the bilayer (7) in such a way that the second laminating film (4.2) lies on the carrier film (5) in a planar manner, f) an inner pane (3) is laid onto the second laminating film (4.2), g) the stack of layers comprising outer pane (2), bilayer (7) of first laminating film (4.1) and carrier film (5) having electrically conductive coating (6), second laminating film (4.2), and inner pane (3), is autoclaved in order to form a composite pane (1).