Vehicle sunroof and method of making the same
First Claim
1. A vehicle sunroof comprising:
- a relatively thin film preform comprising a relatively thin sheet of clear plastic material and a relatively thin material layer having a variable optical transmission such that its opacity changes as voltage is applied thereto, said relatively thin film having opposed surfaces; and
a relatively thick substrate layer being relatively thicker in comparison with said relatively thin film and made of clear plastic material having opposed surfaces curved into a vehicle sunroof configuration,said relatively thin sheet and said relatively thick substrate layer being formed from a same type of clear plastic materialsaid relatively thick substrate layer being adhered to one surface of said relatively thin film while in contact therewith in a molten state under heat and pressure within a cavity defined by two generally parallel curved die surfaces of cooperating injection molding dies so that upon solidification the surfaces of said relative thin film are retained in a curved configuration in generally parallel coextensive relation to corresponding curved surfaces of said relatively thick substrate layer.
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Abstract
The present invention relates to a vehicle sunroof having variable optical transmission and a method for making the same. Specifically, a vehicle sunroof is provided that, in accordance with the present invention, comprises a relatively thin film having variable optical transmission and a relatively thick substrate layer of clear plastic material adhered to a surface of the relatively thin film. The relatively thin film is positioned in a first molding die of a pair of injection molding dies such that it is adjacent a surface of the first die. The relatively thick substrate layer is adhered to one surface of the relatively thin film while in contact therewith in a molten state under heat and pressure within a cavity defined by the injection molding dies.
30 Citations
32 Claims
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1. A vehicle sunroof comprising:
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a relatively thin film preform comprising a relatively thin sheet of clear plastic material and a relatively thin material layer having a variable optical transmission such that its opacity changes as voltage is applied thereto, said relatively thin film having opposed surfaces; and a relatively thick substrate layer being relatively thicker in comparison with said relatively thin film and made of clear plastic material having opposed surfaces curved into a vehicle sunroof configuration, said relatively thin sheet and said relatively thick substrate layer being formed from a same type of clear plastic material said relatively thick substrate layer being adhered to one surface of said relatively thin film while in contact therewith in a molten state under heat and pressure within a cavity defined by two generally parallel curved die surfaces of cooperating injection molding dies so that upon solidification the surfaces of said relative thin film are retained in a curved configuration in generally parallel coextensive relation to corresponding curved surfaces of said relatively thick substrate layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 31)
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16. A method of forming a vehicle sunroof having variable optical transmission comprising:
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providing a relatively thin film preform comprising a relatively thin sheet of clear plastic material and a relatively thin material layer having variable optical transmission such that its opacity changes as voltage is applied thereto, said relatively thin film having opposed surfaces; mounting said relatively thin film preform, including said relatively thin sheet of clear plastic material and said relatively thin material layer having variable optical transmission, adjacent a curved die surface of a molding die arranged to be disposed in cooperating relation with a second molding die having a similarly shaped curved die surface; disposing the first and second molding dies in cooperating relation so as to bring the two curved die surfaces into generally parallel relation to form a die cavity with a spacing between the two curved die surfaces substantially greater than the thickness of said relatively thin film; and injection molding a clear plastic material of a same type as said clear plastic material of said relatively thin sheet under heat and pressure within the die cavity between the two generally parallel curved die surfaces so as to form a molded clear plastic material adhered to said relatively thin film, said molded clear plastic material and said adhered relatively thin film constituting a sunroof having curved surfaces conforming to the two curved die surfaces of said molding dies, said sunroof comprising said relatively thin film, including said relatively thin sheet of clear plastic material and said relatively thin material layer having said variable optical transmission, and a relatively thicker substrate layer comprising said clear plastic material molded in adhered relation to said relatively thin film, said relatively thicker substrate layer being relatively thicker in comparison with said relatively thin film. - View Dependent Claims (17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 32)
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Specification