Encapsulated plastic panel and method of making the same

• US 10,052,850 B2
• Filed: 09/01/2015
• Issued: 08/21/2018
• Est. Priority Date: 05/01/2007
• Status: Active Grant

• Current Assignee: Exatec, LLC (Government of Saudi Arabia)
• Original Assignee: Exatec, LLC (Government of Saudi Arabia)
• Inventors: Weiss, Keith D., Gasworth, Steven M., Grandhee, Sunitha K., Hedderich, Wilfried
• Primary Examiner(s): Polley, Christopher
• Application Number:
  US14/842,164
• Publication Number:
  US 20150367612A1
• Time in Patent Office: 1,085 Days
• Field of Search: None
• CPC Class Codes: B29C 2795/00 Printing on articles made from plastics or substances in a plastic state
• CPC Class Codes: B29C 45/14336 Coating a portion of the article, e.g. the edge of the article B29C45/14573 and B29C45/14598 take precedence
• CPC Class Codes: B29C 45/14434 Coating brittle material, e.g. glass B29C45/14377, B29C45/14418 take precedence
• CPC Class Codes: B29C 45/14811 Multilayered articles B29C45/14827 takes precedence
• CPC Class Codes: B29C 70/763 the edges being disposed in a substantial flat plane
• CPC Class Codes: B29K 2995/002 Coloured
• CPC Class Codes: B29K 2995/0025 Opaque
• CPC Class Codes: B29K 2995/0087 Wear resistance
• CPC Class Codes: B29L 2031/30 Vehicles, e.g. ships or aircraft, or body parts thereof vanes or blades B29L2031/08, air bags B29L2022/027
• CPC Class Codes: B29L 2031/778 Windows profiled elements for making window frames B29L2031/005, windscreens B29L2031/3052
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/20 Inorganic coating
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2255/28 Multiple coating on one surface
• CPC Class Codes: B32B 2305/72 Cured, e.g. vulcanised, cross-linked
• CPC Class Codes: B32B 2307/41 Opaque
• CPC Class Codes: B32B 2307/584 Scratch resistance
• CPC Class Codes: B32B 2307/712 Weather resistant
• CPC Class Codes: B32B 2605/006 Transparent parts other than made from inorganic glass, e.g. polycarbonate glazings
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/365 : comprising polycarbonates
• CPC Class Codes: B32B 38/00 : Ancillary operations in connection with laminating processes
• CPC Class Codes: B32B 38/145 : Printing
• CPC Class Codes: B60J 1/00 : Windows; Windscreens; Accessories therefor B60J10/00 takes precedence; air curtains instead of windows B60J9/04 ; sealing strips for windshields B60J10/70; sealing sash guides for sliding window panes B60J10/74; glass partitions inside vehicles to protect occupants against personal attack B60R21/12
• CPC Class Codes: B60J 7/00 : Non-fixed roofs; Roofs with movable panels , e.g. rotary sunroofsB60J10/00 takes precedence; window aspects B60J1/00; fixed roofs B62D25/06; mechanisms for operating wings E05F11/00, E05F15/00
• CPC Class Codes: B62D 65/06 : the sub-units or components being doors, windows, openable roofs, lids, bonnets, or weather strips or seals therefor assembling sealing arrangements with vehicle parts, e.g. doors, windows B60J10/45
• CPC Class Codes: C09D 11/101 : Inks specially adapted for printing processes involving curing by wave energy or particle radiation, e.g. with UV-curing following the printing
• CPC Class Codes: C09D 11/104 : Polyesters
• CPC Class Codes: Y10T 428/239 : Complete cover or casing
• CPC Class Codes: Y10T 428/24777 : Edge feature

Abstract

An economical method of manufacturing a plastic glazing panel having an encapsulation for aesthetic purposes and to enhance the sealing of the glazing panel to the vehicle is presented. This method includes the steps of forming a plastic panel having an A-side and B-side; printing an opaque border from an ink with the border being in contact with the B-side of the panel and substantially encircling the perimeter of the panel; curing the ink of the opaque border; applying a weatherable layer on the printed border and the plastic panel; curing the weatherable layer; depositing an abrasion resistant layer on the weatherable layer; placing the plastic panel into a mold having a soft gasket; injecting an elastomeric material to form an encapsulation that substantially encircles the perimeter of the plastic panel and encompasses the A-side; B-side and edge of the plastic panel; and removing the plastic panel from the mold.

Claims

1. A plastic glazing panel for use as an automotive window or sunroof, the glazing panel comprising:

a plastic substrate having an A-side major surface, a B-side major surface, and an edge;

a plastic film with an ink cured on the plastic film, wherein the plastic film is disposed on the B-side major surface;

wherein the ink forms an opaque border on the B-side major surface, along the edge;

a first weatherable layer stacked onto the plastic film;

a first abrasion resistant layer stacked onto the first weatherable layer and opposite the plastic film;

wherein the first abrasion resistant layer comprises a silicon oxy-carbide, a hydrogenated silicon oxy-carbide, or a mixture or blend thereof;

a first encapsulation layer proximal to the edge;

wherein the first encapsulation layer is in contact with the first abrasion resistant layer; and

a first adhesion promoter layer located between the first abrasion resistant layer and the first encapsulation layer, wherein the first adhesion promoter layer comprises an adhesion promoter and a urethane adhesive.

2. The plastic glazing panel of claim 1, wherein the ink comprises a binder selected from the group consisting of a polyester-based, polycarbonate-based, and acrylate-based binder.

3. The plastic glazing panel of claim 1, wherein a thickness of the ink is 4 to 20 micrometers.

4. The plastic glazing panel of claim 1, wherein the opaque border encircles a viewing area.

5. The plastic glazing panel of claim 1, wherein the ink comprises a colorant, a filler, a surfactant, a defoamer, a tackifier, an adhesion promoter, a viscosity promoter, a weatherability additive, or a combination comprising at least one of the foregoing.

6. The plastic glazing panel of claim 1, wherein the ink comprises a hindered amine, a UV absorber molecule, or a combination comprising at least one of the foregoing.

7. The plastic glazing panel of claim 1, wherein the first encapsulation layer is part of a single encapsulation that wraps around the edge and encompasses at least a portion of the A-side major surface, the B-side major surface, and the edge of the plastic substrate and/or wherein the first encapsulation layer is one selected from the group consisting of polyvinyl chloride (PVC), thermoplastic elastomers, urethanes, and thermoplastic olefins.

8. The plastic glazing panel of claim 1, wherein the plastic film is in contact with the first weatherable layer.

9. The plastic glazing panel of claim 1, wherein the plastic substrate is selected from the group consisting of polycarbonate, acrylic, polyarylate, polyester, polysulfone, and a copolymer or mixture thereof.

10. The plastic glazing panel of claim 1, wherein the first weatherable layer is one selected from the group consisting of silicones, polyurethanes, acrylics, polyesters, epoxies, and a copolymer or mixture thereof.

11. The plastic glazing panel of claim 10, wherein the first weatherable layer uses ultraviolet absorbing (UVA) molecules to protect the plastic substrate from UV radiation.

12. The plastic glazing panel of claim 1, wherein the first weatherable layer is made up of a primer and a topcoat comprising a silicon hardcoat.

13. The plastic glazing panel of claim 1, wherein the first weatherable layer is made up of a primer and a topcoat;

wherein the primer layer comprises an acrylic, a polyester, an epoxy, or a combination comprising at least one of the foregoing; and

wherein the topcoat layer comprises polymethylmethacrylate, polyvinylidene fluoride, polyvinylfluoride, polypropylene, polyethylene, polyurethane, polymethacrylate, polyurethane-acrylates, polyacrylate, polyvinylidene fluoride, a silicone, or a combination comprising at least one of the foregoing.

14. The plastic glazing panel of claim 1, wherein the ink comprises a UV cured ink.

15. The plastic glazing panel of claim 1, further comprising a second weatherable layer, a second abrasion resistant layer, and a second encapsulation layer;

wherein the plastic film comprises a film primary side and a film secondary side;

wherein the film primary side is in contact with the B-side major surface of the plastic substrate;

the first weatherable layer has a first weatherable primary side and a first weatherable secondary side;

wherein the first weatherable primary side is in contact with the film secondary side;

the first abrasion resistant layer has a first abrasion primary side and a first abrasion secondary side;

wherein the first abrasion primary side is in contact with the first weatherable secondary side;

the first encapsulation layer located on the first abrasion secondary side of the first abrasion resistant layer, proximal to the edge of the plastic substrate;

the first adhesion promoter layer located between the first abrasion secondary side and the first encapsulation layer;

the second weatherable layer has a second weatherable primary side and a second weatherable secondary side, wherein the second weatherable secondary side is in contact with the A-side major surface of the plastic substrate;

the second abrasion resistant layer has a second abrasion primary side and a second abrasion secondary side;

wherein the second abrasion secondary side is in contact with the second weatherable primary side;

the second encapsulation layer located on the second abrasion primary side of the second abrasion resistant layer, proximal to the edge of the plastic substrate;

an optional second adhesion promoter layer located between a second abrasion primary side and the second encapsulation layer.

16. The plastic glazing panel of claim 15, wherein the second abrasion resistant layer is one selected from the group consisting of aluminum oxide, barium fluoride, boron nitride, hafnium oxide, lanthanum fluoride, magnesium fluoride, magnesium oxide, scandium oxide, silicon monoxide, silicon dioxide, silicon nitride, silicon oxy-nitride, silicon oxy-carbide, hydrogenated silicon oxy-carbide, silicon carbide, tantalum oxide, titanium oxide, tin oxide, indium tin oxide, yttrium oxide, zinc oxide, zinc selenide, zinc sulfide, zirconium oxide, zirconium titanate, and a mixture or blend thereof.

17. The plastic glazing panel of claim 15, wherein the first encapsulation layer and the second encapsulation layer are part of a single encapsulation that wraps around the edge of the plastic glazing panel.

18. The plastic glazing panel of claim 15, wherein the optional second adhesion layer is present.

19. A plastic glazing panel for use as an automotive window or sunroof, the glazing panel comprising:

a plastic substrate having an A-side major surface, a B-side major surface, and an edge;

a plastic film with an ink cured on the plastic film, wherein the plastic film is disposed on the B-side major surface;

wherein the ink forms an opaque border on the B-side major surface, along the edge;

a first weatherable layer stacked onto the plastic film;

a first abrasion resistant layer stacked onto the first weatherable layer and opposite the plastic film;

wherein the first abrasion resistant layer comprises a hydrogenated silicon oxy-carbide;

a first encapsulation layer proximal to the edge;

wherein the first encapsulation layer is in contact with the first abrasion resistant layer; and

a first adhesion promoter layer located between the first abrasion resistant layer and the first encapsulation layer, wherein the adhesion promoter layer comprises an adhesion promoter and a urethane adhesive.