Glazing system for vehicle tops and windows

• US 20070026235A1
• Filed: 03/16/2006
• Published: 02/01/2007
• Est. Priority Date: 07/27/2005
• Status: Active Grant

• Current Assignee: Exatec, LLC (Government of Saudi Arabia)
• Original Assignee: Exatec, LLC (Government of Saudi Arabia)
• Inventors: Chen, Meng, Grandhee, Sunitha, Sargent, Johathan, Gasworth, Steven
• Granted Patent: US 8,216,679 B2
• Time in Patent Office: Days
• US Class Current: 428/411.100
• CPC Class Codes: C08J 2369/00 Characterised by the use of polycarbonates; Derivatives of polycarbonates
• CPC Class Codes: C08J 7/0423 with at least one layer of inorganic material and at least one layer of a composition containing a polymer binder
• CPC Class Codes: C08J 7/043 Improving the adhesiveness of the coatings per se, e.g. forming primers adhesives in the form of films or foils characterised by the primer layers between the polymer carriers and the adhesives C09J7/50
• CPC Class Codes: C08J 7/046 Forming abrasion-resistant coatings; Forming surface-hardening coatings
• CPC Class Codes: C23C 16/401 containing silicon
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31507 Of polycarbonate
• CPC Class Codes: Y10T 428/31511 Of epoxy ether
• CPC Class Codes: Y10T 428/31663 As siloxane, silicone or silane
• CPC Class Codes: Y10T 428/31786 Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31935 Ester, halide or nitrile of addition polymer

Abstract

A glazing system and method for vehicle tops and windows is described therein. The system includes a panel having a top side and a bottom side, a first protective coating deposited on the top side and second protective coating deposited on the bottom side. The protective coatings provide protection from weathering and abrasion.

Claims

1. A glazing assembly comprising:

a plastic panel having a first side surface and a second side surface;

a first protective coating system deposited on the first side surface, the first protective coating system further comprises a weathering layer and at least two abrasion-resistant layers;

a second protective coating system deposited on the second side surface, the second protective coating system further comprises at least two abrasion-resistant layers; and

wherein the first and second protective coating systems provide protection from weathering and abrasion.

2. The glazing assembly of claim 1, wherein the weathering layer further comprises multilayer coating having interlayers.

3. The glazing assembly of claim 2, wherein at least one of the multilayer coating having interlayers contains a UV absorbing molecules.

4. The glazing assembly of claim 2, wherein the multilayer coating interlayers comprise an acrylic primer and a silicone hard-coat.

5. The glazing assembly of claim 1, wherein the abrasion resistant layers are vacuum deposited layers.

6. The glazing assembly of claim 5, wherein the vacuum deposited layers are PECVD deposited layers.

7. The glazing assembly of claim 6, wherein the PECVD deposited layers are arc-PECVD deposited layers.

8. The glazing assembly of claim 5, wherein the abrasion resistant layers are made from at least one of a silioxane, a silicon oxy-carbide, and a hydrogenated silicon oxy-carbide.

9. The glazing assembly of claim 1 wherein each of the abrasion-resistant layers are made from different chemical compositions.

10. The glazing assembly of claim 1 wherein each of the abrasion-resistant layers are made from substantially similar chemical compositions.

11. The glazing assembly of claim 1, further comprising a decorative ink layer disposed between the plastic panel and the second protective coating system.

12. The glazing assembly of claim 1, further comprising a weathering layer located between the plastic panel and the second protective coating system.

13. The glazing assembly of claim 1, wherein one of the at least two abrasion-resistant layers of the first protective coating system include a UV absorbing species.

14. The glazing assembly of claim 13, wherein the UV absorbing species is derived from one of vinyl-D4, D4, HMDSO, and TMDSO.

15. The glazing assembly of claim 1, wherein one of the at least two abrasion-resistant layers of the second protective coating system include a UV absorbing species.

16. The glazing assembly of claim 15, wherein the UV absorbing species is derived from one of vinyl-D4, D4, HMDSO, and TMDSO.

17. The glazing assembly of claim 1, wherein the plastic panel is constructed of a thermoplastic resin.

18. The glazing assembly of claim 17, wherein the thermoplastic resin is one of polycarbonate, acrylic, polyarylate, polyester, and polysulfone.

19. The glazing assembly according to claim 1, wherein the plastic panel is a transparent panel.

20. A method of making a glazing assembly, the method comprising the steps of:

providing a plastic panel having a first side surface and a second side surface;

performing a first procedure comprising the steps of preheating the first side surface of the plastic panel to a first temperature and depositing a first abrasion resistant layer to the first side surface using a first reactive agent; and

performing a second procedure comprising the steps of preheating the second side surface of the plastic panel to a second temperature and depositing a second abrasion resistant layer to the second side using a second reactive reagent and a vacuum deposition process.

21. The method of claim 20, wherein

the second temperature is about 40°

C. to 50°

C.;

the second reactive reagent is D4;

the second abrasion resistant layer is deposited using a second arc current of less than about 60 amps/arc, a second reactive reagent flow rate of less than about 170 sccm/arc, and a second oxygen flow rate of less than about 400 sccm/arc; and

the first abrasion resistant layer is deposited using a first arc current of less than about 60 amps/arc, a first reactive reagent flow rate of less than about 170 sccm/arc, and a first oxygen flow rate of less than about 950 sccm/arc.

22. The method of claim 21, wherein

the second arc current is between about 30 to 45 Amps/arc, the second reactive reagent flow rate is between about 50 and 150 sccm/arc, the second oxygen flow rate is less than about 400 sccm/arc;

and

the first arc current is about between about 30 and 45 Amps/arc, the first reactive reagent flow rate is between about 50 to 150 sccm/arc and the first oxygen flow rate is between about 700 and 900 sccm/arc.

23. The method of claim 21, wherein

the second arc current is about 34 Amps/arc, the second reactive reagent flow rate is about 125 sccm/arc, the second oxygen flow rate is about zero;

and

the first arc current is about 37 Amps/arc, the first reactive reagent flow rate is about 150 sccm/arc and the first oxygen flow rate is about 800 sccm/arc.

24. The method of claim 21, wherein

the second arc current is about 31 Amps/arc, the second reactive reagent flow rate is about 125 sccm/arc, the second oxygen flow rate is about 50 sccm/arc;

and

the first arc current is 37 Amps/arc, the first reactive reagent flow rate is about 150 sccm/arc, and the first oxygen flow rate is about 800 sccm/arc.

25. The method of claim 20, further comprising the step of depositing a printed ink on the second side surface of the plastic panel.

26. The method of claim 20, wherein

the first temperature is about 40°

C. to 50°

C.;

the first reactive agent is D4;

the second reactive agent is vinyl-D4;

the second abrasion resistant layer is deposited using a first arc current between about 34 to 43 Amps/arc, a second reactive reagent flow rate of about 20 sccm/arc, a second oxygen flow rate of less than about 300 sccm/arc; and

the first abrasion resistant layer is deposited using a first arc current of about 34 Amps/arc, a first reactive reagent flow rate of about 125 sccm/arc, and a first oxygen flow rate of about 800 sccm/arc.

27. The method of claim 20, further comprising the step of depositing a weathering layer between the second side surface of the plastic panel and the second abrasion resistant layer.

28. The method of claim 27, wherein the weathering layer includes an acrylic primer and a silicone hard-coat.

29. The method of claim 20, wherein

the first temperature is about 50°

C. to 60°

C.;

the second reactive reagent is D4;

the second abrasion resistant layer is deposited using a second arc current between about 30 to 45 amps/arc, a second reactive reagent flow rate between about 50 to 150 sccm/arc, and a second oxygen flow rate of less than about 400 sccm/arc; and

the first abrasion resistant layer is deposited using a first arc current between about 30 to 45 amps/arc, a first reactive reagent flow rate between about 50 to 150 sccm/arc, and a first oxygen flow rate between about 700 to 950 sccm/arc.

30. The method of claim 29, wherein the second arc current is about 34 Amps/arc, the second reactive reagent flow rate is about 125 sccm/arc, and the second oxygen flow rate is about 50 sccm/arc.

31. The method of claim 29, wherein the first arc current is about 37 Amps/arc, the first reactive reagent flow rate is about 150 sccm/arc, and the first oxygen flow rate is about 800 sccm/arc.

32. The method of claim 29, further comprising the step of depositing a weathering layer between the first side surface and the first abrasion resistant layer.

33. The method of claim 32, further comprising the step of depositing a primer between the first side surface and the weathering layer.

34. The method of claim 20, further comprising the step of performing the at least a portion of the second procedure during the first procedure.

35. The method of claim 20, further comprising the step of performing the first procedure before the second procedure.

36. The method of claim 20, further comprising the step of performing the second procedure before the first procedure.