WO2024116075A1

WO2024116075A1 - Edge sealed laminate with insert and method of production

Info

Publication number: WO2024116075A1
Application number: PCT/IB2023/061988
Authority: WO
Inventors: Natalia Andrea RUEDA GUERRERO; Stefan GOSSEN; Juan Felipe CASTRO LANDINEZ; Noelia CABRERA; Mauricio SALAZAR ASTETE; Daniel ESTRADA DIAGO; Katherine TOFEÑO
Original assignee: AGP Worldwide Operations GmbH
Current assignee: AGP Worldwide Operations GmbH
Priority date: 2022-11-28
Filing date: 2023-11-28
Publication date: 2024-06-06
Anticipated expiration: 2025-05-28

Abstract

The complexity of modern automotive glazing has been increasing as the industry moves towards full autonomous vehicles and as consumers demand increased levels of comfort, convenience, and safety. Laminates often have components inserted within the laminate. Fabrication of such parts can be challenging. Inserts can lead to breakage, distortion, and delamination. In addition, some of currently used and desired inserts are not compatible with the vacuum, heat, and pressure of the process and some should also be protected from UV and the ingress of water. The innovative hybrid lamination and edge seal method of the invention is compatible with inserts that would not be possible or practical to laminate with the typical automotive lamination process. A pre-assembly comprising a glass layer and an interlayer is first formed and then the insert is laminated by means of a liquid optically clear adhesive and the edge is sealed with a thermoplastic material.

Description

EDGE SEALED LAMINATE WITH INSERT AND METHOD OF PRODUCTION

FIELD OF THE INVENTION

The invention relates to the field of automotive glazing.

BACKGROUND OF THE INVENTION

With the trend towards full autonomous vehicles, as well as consumer demand for increased levels of comfort, convenience, and safety, the complexity of modern automotive glazing has been increasing at a rapid rate. Often times, the glazing is used as a platform for and becomes an integral permanent part of new and innovative technology.

This trend dates back to at least the 1970s when antennas were first embedded in laminated windshields. In the 1980s we started to see screen print silver antennas printed on the glazing. The 1990s brought us telematic systems that utilized glazing mounted GPS and cellular antennas. Today, many automotive laminates are produced with components supporting several types of technology embedded within the laminate. These include various performance films, solar reflecting, low-e and anti-reflective coatings, embedded wire heating, embedded antennas, sensors, and lighting.

Today, almost all of the vehicles being produced in North America include at least some minimal level of driver assistance as standard equipment. Many of the automotive manufacturers are now making driver assistance systems, which were an expensive option not too many years ago, standard equipment on many if not all of their models.

One major automotive manufacturer has been including as standard equipment, on most models, a driver assist package that used to be a $3,000+ option. The system provides: adaptive cruise control, lane keep assist, sway warning, pre-collision braking, and throttle management. The system utilizes two cameras mounted on either side of the rear-view mirror as well as several sensors mounted in other locations. To date they have delivered over one million vehicles with this technology. The windshield is an integral part of this system.

Laminated glazing lends themselves well to many of the innovative technologies. For one, the glazing surrounds and encloses the passenger compartment and occupies a substantial portion of the cabin interior and vehicle exterior surface area. It is also possible to embed various materials and devices within the soft polymer layers of the glazing where they are protected by the hard transparent glass layers. We shall refer to the several types of materials, components and devices that are embedded within the laminate as inserts. We can classify inserts as passive or active. Heat reflecting solar control films are an example of a passive insert which requires no power. Active inserts are those that require an electrically conductive connection from the insert to the exterior of the glazing. Films on which the level of light transmission can be varied electrically are an example of active inserts. Likewise, laminates containing LED lights, touch sensors, heated defroster circuits, antennas and other electrical devices are also active inserts.

Laminates, in general, are articles comprised of multiple layers of thin, relative to their length and width, material, with each thin layer having two oppositely disposed major faces, typically of uniform thickness, which are permanently bonded to one and other across at least one major face of each layer. The layers of a laminate may alternately be described as sheets or plies. In addition, the glass layers of a glazing may be referred to as panes.

Laminated safety glass is made by bonding two layers of annealed glass together using a polymer bonding layer comprised of a thin sheet of transparent thermoplastic (interlayer).

Safety glass is glass that conforms to all applicable industry and government regulatory safety requirements for the application.

Annealed glass is glass that has been slowly cooled from the bending temperature down through the glass transition range. This process relieves any stress left in the glass from the bending process. Annealed glass breaks into large shards with sharp edges. When laminated safety glass breaks, the shards of broken glass are held together, much like the pieces of a jigsaw puzzle, by the polymer layer helping to maintain the structural integrity of the glass. A vehicle with a broken windshield can still be operated. The polymer layer also helps to prevent penetration by objects striking the laminate from the exterior and in the event of a crash occupant retention is improved.

All windshields are required by law to be annealed laminated safety glass.

Tempered glass has a layer of high compression on the outside surfaces of the glass, balanced by tension on the inside of the glass which is produced by the rapid cooling of the hot softened glass. When tempered glass breaks, the tension and compression are no longer in balance and the glass breaks into small beads with dull edges. Tempered glass is much stronger than annealed laminated glass. Due to the lower cost and higher strength of tempered glass, tempered glass has been favored for all but the windshield position where tempered glass is not permitted. While laminated glass is only required for the windshield, it is being used in other positions increasingly. On some higher end vehicles, laminated glass is being used for the doors rather than tempered glass to improve safety and security. Smash and grab attacks, where an assailant gains access by breaking a vehicle window, often while occupied, are on the rise. A tempered window can be breached in a fraction of a second. With a laminated side window, intrusion time into the vehicle by an attacker is significantly increased which may provide enough delay to overcome the criminal's advantage of surprise and provide sufficient time for escape. Also, laminated glass, when bonded to the opening can improve occupant retention in the event of an accident.

In addition to the safety and security benefits a standard laminate provides improved sound dampening. The use of a laminate also enables and facilitates the use of heat reflecting solar control coatings and films which cannot be used with single layer tempered glass.

The growing use of laminates for vehicle openings other than just the windshield expands the opportunities to incorporate added technology into the glazing.

The enhanced characteristics of a laminated window are enabled in large part by the polymer bonding layer holding the two glass layers together.

The polymer bonding layer (interlayer) has the primary function of bonding the major faces of adjacent layers to each other. The material selected is typically a clear thermoplastic polymer. The polymer interlayer used to laminate all safety glass windshields is index matched to the index of refraction of the glass to prevent internal reflections. While there are numerous transparent plastics, few have the required level of adhesion to glass and can survive the extremes of temperature and UV exposure for the life of the vehicle.

For automotive use, the preferred bonding layer (interlayer) is polyvinyl butyral (PVB). In addition to being the most economical, PVB has excellent adhesion to glass and is optically clear once laminated.

Automotive interlayers are made by an extrusion process. To facilitate the handling of the polymer sheet during assembly the surfaces of the interlayer are normally embossed, as a smooth surface tends to stick to the glass trapping air and making it difficult to position the interlayer on the glass. Standard thicknesses for automotive PVB interlayer at 0.38 mm and 0.76 mm (15 and 30 mil).

Automotive PVB is a highly engineered and optimized material. PVB has been specially formulated for automotive use. The formulas and manufacturing methods have continually been improved over the course of several decades. Even still, all grades of PVB cannot be used for all automotive laminates. Laminates that utilize a coating on one of the surface internal to the laminate may need to use a specially formulated PVB due to the difference in adhesion between the PVB and glass versus PVB and the coating. If the adhesion is too high, the PVB will tear rather than stretch. If the adhesion is too low, the glass will not adhere to the PVB leading to spalling.

As received from the manufacturer, interlayers are not transparent. They are translucent and have an embossed surface. Heat and pressure are required to bond the interlayer to the glass and to make the interlayer transparent and optically clear. The interlayer should first be processed in an autoclave to eliminate the embossing and optically convert to a transparent state. In the autoclave, the assembled layers of the laminate are subject to high pressure and temperature. The temperature is elevated into the glass transition range of the interlayer where the pressure forces the viscose thermoform plastic to flow and take on the shape of the glass layers.

The performance of the PVB is so critical to safety that manufacturers sample and test laminated automotive glazing in production on a regular basis in order to meet regulatory requirements.

As the interlayer is soft and pliable, it is possible to embed some of the various articles needed to implement additional functionality within the laminate.

As a rule of thumb, an insert can be laminated if the thickness is not more than 1/3 of the total thickness of the interlayer. The interlayer is soft at room temperature. During the lamination process, the interlayer is held at an elevated temperature under high pressure and will flow to accommodate the insert if the insert is thin enough. The maximum insert thickness will depend upon other factors such as the other dimensions of the object, the thickness of the glass, the strength of the glass, the specific interlayer and the time, temperature, and pressure of the lamination cycle. If the object is too thick, the glass may break. Objectionable distortion can also occur. With all other factors remaining the same, thinner is always better with respect to the risk of breakage and distortion.

In the event of an impact in the area of the insert, the laminate should still meet regulatory requirements for penetration resistance and spalling of the glass. As a result, it may be necessary to provide an additional sheet of interlayer so that the insert is captured between the two interlayer sheets or to bond the insert to the glass surface itself. With smaller inserts, an adhesive may be used to bond the insert to the glass. One common active insert is variable light transmission film (VLT). To control the level of light transmission through the laminate, there are a number of technologies available: electrochromic, photochromic, thermochromic and electric field sensitive films which can be incorporated into laminated glass. Electric field sensitive films include Suspended Particle Device (SPD) films, Liquid Crystal (LC) and Polymer Dispensed Liquid Crystal (PDLC) films. All three can quickly change light transmittance, going from light to dark and back, in response to an electrical field. Another type of VLT film, electrochromic (EC), switches in response to an electrical current. PNLC (Polymer Network Liquid Crystal) is yet another type of VLT film.

Variable light transmission films, as well as other performance films are sandwiched between two sheets of interlayer due to the large area that they cover. One sheet of interlayer is required for each of the two major faces of the insert so as to bond each film face to the other layers of the laminate.

Due to the thickness of the VLT film in the area where the bus bars and connectors are attached, the film can be difficult to laminate even with two full thickness layers of interlayer.

With VLT films a thicker insert can be accommodated than would otherwise be possible due to the two sheets of interlayer required. As an example, applying the 1/3 rule of thumb, with an 0.76 mm and an 0.36 mm interlayer, we can have an insert with a thickness of up to 0.36 mm. As VLT films draw very little power and as a result do not require thick or wide bus bars, that maximum thickness is typically sufficient. The only area where we may have a problem is where the connector that brings power into the laminate is attached to the bus bar, which may increase the thickness.

Wire embedded heated laminates as well as laminates with VLT films, also require the addition of bus bars to distribute the electrical power needed, further increasing the thickness in the bus bar areas. With embedded wire heated circuit bus bars, a substantial amount of current is drawn requiring thicker and wider bus bars. When a single layer of interlayer is used the maximum thickness of the insert is less than that of a VLT film with two layers of interlayer. When this is the case, it is often necessary to "carve" a trough in the PVB for the bus bars.

Active inserts comprising LEDs, touch sensors, light fibers, sensors, and other devices due to their thickness and irregular shape can present a challenge when working with polymer interlayer sheets.

It is not so much the absolute thickness as the rate of change in thickness that causes problems. If a film of uniform thickness extends to the edge of glass, then the only issue will be wrinkling of the film as the flat film is forced to conform to the curvature of the glass. In this case, the 1/3 rule does not apply. However, it is typical to cut back the film from the edge of glass so as to protect the edge of the film from exposure to the external elements and to minimize the amount of film needed. This step change in thickness is where problems can occur. If the change is too great, a spacer may be needed. One method used to prevent breakage has been to insert a spacer running from the edge of the film to the edge of glass. In this way, the abrupt step change in thickness at the edge of the film is avoided.

If the insert is ~l/3 the thickness of the interlayer, then the lamination may be successful. Other process parameters also have to be adjusted. It is advisable to heat and soften the interlayer before vacuum is applied and to ramp up pressure at a slower rate than would otherwise be used. A higher temperature may also be needed to allow the interlayer to better flow.

Laminates with inserts share some common disadvantages.

The lamination process includes the steps of assembling the layers, removing air from the assembly, and then processing the assembly at an elevated temperature and pressure in an autoclave.

Prior to the autoclave step, it is necessary to remove as much air as possible from the assembly. There are two widely used methods to remove the air from a laminate, the vacuum method, and the pinch roller method. In both processes, the laminate is heated so as to partially melt the interlayer causing it to adhere to the glass layers and seal the edges. The assembly is heated to a temperature that is high enough to make the interlayer tacky and remove the embossing pattern on the interlayer surface but not high enough to completely melt the interlayer and make it optically transparent.

For most ordinary laminates, which do not have extreme curvature or inserts, the pinch roller system is used. The heated assembly is passed through a set of soft flexible rollers, curved to the average shape of the laminate which are used to pinch the two layers together adhering the glass layers to the tacky interlayer and forcing the air out. The small amount of air remaining is forced out by the high pressure of the autoclave.

The vacuum method is used to evacuate the air from the laminate and adhere the glass layers to the interlayer. The entire assembly is placed inside of a bag, or a channel is applied to the periphery. The assembly is heated with the vacuum applied and atmospheric pressure forces the assembly together. This method is used for most laminates with inserts including performance films. As one can imagine, the labor associated with the vacuum method is much higher. In general, additional workers are needed to apply and remove the channel or bag whereas the pinch roller method is largely automated. The duration of the lamination process may also need to be increased.

Even when successfully laminated, the variations in thickness caused by the inserts can cause optical distortion and areas of tension and compression across the surface.

The areas of high tension may lead to the premature failure of the glass. The probability of failure is a function of stress, duration, and time. If there is any stress locked in the glass, the duration goes to infinity and the probability of breakage goes to 100% although the time that it may take can be quite lengthy at low levels of stress. At any rate, the probability of breakage will be greater than zero.

The bigger issue is that we find that some proposed inserts are not able to survive the lamination process. In these cases, the only option is to use what is known as the optical bonding method accomplished by using a Liquid Optically Clear Adhesive (LOCA) or comparable product, a process also known as cold lamination.

With conventional solid polymer interlayers, components are flat and a fraction of the thickness of the interlayer. Further, the more expensive vacuum channel/bag method should be used to laminate the glazing. Even when lamination is successful, yield loss, the potential for breakage and distortion will all tend to be higher.

It would be advantageous to fill the gap between the layers of the laminate with a viscous, transparent, optically clear, index of refraction matched, liquid adhesive, which would fill and conform to the gap between layers and to the contours of the various inserts that may be needed. The liquid also should have sufficient adhesion to the glass and other inserts and the capability to be cured after the gap has been filled.

This type of product has been developed and is commonly known as a liquid optically clear adhesive or LOCA. It is also known as laminating resin. With a LOCA, the only restriction on inserts is that they can be no thicker than the design gap between the layers. The finished laminate will have no residual stress caused by the thickness of the insert or surface mismatch. In fact, it has been found that the optical quality of a laminate made with a LOCA is sometimes far better than that of the same glass made with an interlayer.

As the LOCA is a liquid, the LOCA has to be contained within the two glass layers of the laminate while the void is filled and cured. This is performed with the help of a dam. The dam is applied to the interior glass surfaces creating a gap between the two glass surfaces which is subsequently filled with a LOCA.

While optically clear thermoset LOCAs have been available for many years, they have primarily been used for non-glazing applications where the gap between the laminate layers is very large and/or irregular.

Attempts have been made to use LOCAs in place of the solid interlayer for automotive applications. LOCAs that are UV cured are preferred due to their short cure time.

There are a limited number of LOCAs that are suitable for automotive use. Any product that is used in a vehicle should meet the very severe automotive environmental test requirements. The glazing should be able to withstand extremes of temperature ranging from -40 °C to 80 °C, 100% humidity, intense UV exposure, salt exposure and many other requirements. Further, the glazing needs to last for the life of the vehicle. The LOCA should also be environmentally friendly and not toxic.

LOCA is a thermoset resin material. It is in the form of a liquid and should be dispensed or injected into the gap it needs to fill. After injected, it needs to be cured. Curing is the process of polymerization of the resin material. The polymer chains suffer cross-linking which hardens the material. After curing, LOCA resin is completely solid. The curing or hardening process in this case is irreversible. Once cured, the LOCA will never become liquid again.

One of the drawbacks of LOCA laminates uncounted when used to make automotive safety glass is their adhesion. The adhesion to glass can be too high or too low. In either case the penetration resistance of the laminate may not be sufficient to meet regulatory requirements. It can also be difficult to fill the gaps between the two glass layers and the insert with the LOCA and remove all air. It can also be difficult to achieve uniform thickness of the LOCA.

Many of the various LOCAs that are suitable for automotive glazing use are susceptible to degradation from exposure to water. The ingress of water can cause the LOCA to lose its transparency and in extreme cases cause the bond to the glass to weaken allowing the glazing to de-laminate, requiring replacement. Also, the active inserts are also likely to be damaged by exposure to humidity and water. As a result, glazing that is laminated with a LOCA also needs to have an edge seal to protect the LOCA and insert. Likewise, the material used to fabricate the dam may also be sensitive to water.

Like the LOCAs, there are a very limited number of materials that are suitable for use in automotive glazing as an edge seal. The edge should provide a moisture barrier, have good adhesion to glass, the LOCA and the dam material, and last the life of the vehicle. Typically, a combination of materials is used with two or more edge sealants applied increasing cost and complexity.

It would be highly desirable to have a method of lamination and an edge seal that would not have these drawbacks.

BRIEF SUMMARY OF THE INVENTION

A hybrid lamination process comprising both hot and cold lamination is used to enable the lamination of inserts, including heat, pressure or vacuum sensitive inserts that would not otherwise be possible to fabricate, with the use of traditional lamination materials and processes. In the hot lamination portion a sheet of interlayer is laminated to a bent glass layer. The interlayer provides UV protection and penetration resistance. The cold portion then follows. A first dam is applied to the interlayer. The insert is placed over and bonded to the first dam. The volume enclosed is then filled with LOCA forming a first assembly. Next, a second dam is applied to a second glass layer forming a second assembly and this second assembly is joined to the first assembly. The gap between the second glass, dam and insert is filled again with LOCA. Surprisingly, it has been found that ordinary automotive interlayers, the most common one being PVB, which already meets the criteria for glass adhesion and durability is compatible with most dam materials and LOCAs and also provides an adequate moisture resistant edge seal. The interlayer is used to fill the gap between the glass layers extending from the dam to the edge of glass and thus sealing the edge.

ADVANTAGES

• Allows lamination of inserts that would not survive a conventional automotive lamination process.

• Allows for inserts with non-uniform thickness to be laminated.

• Allows for inserts with abrupt changes in thickness to be laminated.

• Reduces or eliminates residual stress caused by inserts.

• Reduces or eliminates optical distortion caused by inserts.

• Provides enhanced optical quality.

DESCRIPTION OF THE DRAWINGS Figure 1A shows a cross section of typical laminate.

Figure IB shows a cross section of typical laminate with coating on surface two and a performance film.

Figure 2 shows an exploded isometric view of laminated roof according to an embodiment of the invention.

Figure 3 shows a top view of the laminated roof in Figure 2.

Figure 4A shows a cross section of pre-assembly with separator and both glass layers according to an embodiment of the invention.

Figure 4B shows an exploded cross section of pre-assembly with separator and both glass layers.

Figure 4C shows an exploded cross section of first and second pre-assemblies with the separator.

Figure 5A shows a Cross section of the first pre-assembly with first dam applied.

Figure 5B shows a Cross section of 5A with insert.

Figure 5C shows a Cross section of 5B with the first LOCA fill.

Figure 6A shows a Cross section of 5C with second dam and second glass layer.

Figure 6B shows a Cross section of 6A with second LOCA fill.

Figure 7A shows a Cross section of 6B with edge seal.

Figure 7B shows a Cross section of 8C with edge seal.

Figure 8A shows a Cross section of the first pre-assembly with the first dam applied.

Figure 8B shows a Cross section of 8A with insert.

Figure 8C shows a Cross section of 8B with the first LOCA fill.

Figure 9A shows a Cross section of 8C with second dam and second glass layer.

Figure 9B shows a Cross section of 9A with second LOCA fill.

Figure 10A shows a cross section of a glazing of this invention similar to Figure 7A, further comprising a second plastic interlayer.

Figure 10B shows a cross section of a glazing of this invention similar to Figure 7B, further comprising a second plastic interlayer.

REFERENCE NUMERALS OF DRAWINGS

2 Glass

4 Plastic Interlayer

6 Obscuration/Black Paint

12 Infrared reflecting film 16 Edge Seal

18 Infrared reflecting coating

20 First Liquid Clear Optical Adhesive (LOCA)

22 Second Liquid Clear Optical Adhesive (LOCA)

24 Insert

26 First Dam

28 Second Dam

30 Separator/ Non-adhesive plastic interlayer

32 First pre-assembly

34 Second pre-assembly

101 Exterior side of glass layer 1 (201), number one surface.

102 Interior side of glass layer 1 (201), number two surface.

103 Interior side of glass layer 2 (202), number 3 surface.

104 Exterior side of glass layer 2 (202), number 4 surface.

201 First glass layer

202 Second glass layer

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure can be understood more readily by reference to the detailed descriptions, drawings, examples, and claims in this disclosure. However, it is to be understood that this disclosure is not limited to the specific compositions, articles, devices, and methods disclosed unless otherwise specified and as such can vary. It is also to be understood that the terminology used herein is for the purpose of describing aspects only and is not intended to be limiting.

Typical automotive laminated glazing cross-sections are illustrated in Figures 1A and IB. The laminate is comprised of two layers of glass 2, the first glass layer, 201 and the second glass layer, 202 that are permanently bonded together by a plastic interlayer 4. In a laminate, the glass surface of the first glass layer 201, which faces the exterior of the laminate is referred to as surface one, 101, or the number one surface. The opposite face of the first glass layer 201 is surface two, 102, or the number two surface. Surface two faces the interior of the glazing. The surface of the second glass layer 202 that faces the exterior of the laminate is referred to as surface four, 104, or the number four surface. The opposite face of the second glass 202 which faces the interior of the glazing is surface three, 103, or the number three surface. Surfaces two, 102, and three, 103 are bonded together by the plastic interlayer 4. An obscuration 6 may also be applied to the glass. Obscurations are commonly comprised of black enamel frit printed on either the number two, 102, or number four surface, 104, or on both. The laminate may have a coating 18 on one or more of the surfaces. The laminate may also comprise a film 12 laminated between at least two plastic interlayers 4 (Figure IB).

The following terminology is used to describe the laminated glazing of the invention.

The term "glass" can be applied to many inorganic materials, including many that are not transparent. For this document we will only be referring to transparent glass. From a scientific standpoint, glass is defined as a state of matter comprising a non-crystalline amorphous solid that lacks the ordered molecular structure of true solids. Glasses have the mechanical rigidity of crystals with the random structure of liquids.

Glass is formed by mixing various substances together and then heating to a temperature where they melt and fully dissolve in each other, forming a miscible homogeneous fluid.

A glazing is an article comprised of at least one layer of a transparent material which serves to provide for the transmission of light and/or to provide for viewing of the side opposite the viewer and which is mounted in an opening in a building, vehicle, wall or roof or other framing member or enclosure.

A laminated glazing can be curved or flat. When curved, the individual layers can be curved separately or simultaneously bent by means of hot bending, such as gravity bending, pressbending or a combination of. When bending glass layers have different compositions, it is advantageous to bend the glass layers separately, one at a time, because each one would request different conditions of bending, for example different temperatures and processing times. Additionally, one of the glass layers could be cold bent, meaning that it conforms to the shape of the other glass layer only during lamination. In that case, usually there are surface tensions created onto the glass that was cold-bent. In most cases the cold-bent glass layer should be strengthened so the surface tensions created during and after the cold-bending could be accounted for.

The types of glass that may be used include but are not limited to the common soda-lime variety typical of automotive glazing as well as aluminosilicate, lithium aluminosilicate, borosilicate, glass ceramics, and the various other inorganic solid amorphous compositions which undergo a glass transition and are classified as glass included those that are not transparent. The glass layers may be comprised of heat absorbing glass compositions as well as infrared reflecting and other types of coatings.

While the focus of the embodiments and discussion is on laminated roofs and laminated side windows, it can be appreciated that the invention is not limited to roofs. The invention may be implemented in any of the other glazing positions of the vehicle. In addition, the invention may be practiced with any type of glazing and is not limited to automotive.

A variety of thermoset LOCAs are available. As the items being laminated are transparent, the most convenient LOCA type for automotive glazing are those that are cured by means of exposure to light. LOCAs are available that are sensitive to and cured at various light frequencies with UV being the most common. However, this is not to be taken as a limitation. LOCAs that are cured by other means may be used and are considered equivalent such as UV light curing, platinum curing, moisture curing, thermal curing, catalyst curing, room temperature curing, or a combination thereof.

The LOCA composition of this invention could comprise any of the following: are selected from the group of epoxy-based adhesive, acrylic-based adhesive, silicone-based adhesive, urethane- based adhesive, and a combination thereof.

The laminated glazing of the present disclosure comprises a first glass layer having an exterior surface oriented towards the outside of the laminated glazing, and an interior surface oriented towards the inside of the laminated glazing; a first plastic interlayer having a length Lj, a width w; and edges, being arranged in between the active film and the interior surface of the first glass layer; an active film, having a length Lf, a width Wf, and edges, wherein the length Lf is smaller than the length Lj, and the width Wf is smaller than the width wi; a first dam located or arranged between said first plastic interlayer and the active film, the first dam being arranged to form a first gap between the first plastic interlayer and the active film; a first curable liquid optically clear adhesive that fills the first gap; a second glass layer having an interior surface oriented towards the inside of the laminated glazing, an exterior surface oriented towards the outside of the laminated glazing, and being disposed such as to form a second gap between the second glass layer interior surface and the active film surface that does not face the first plastic interlayer; a second curable liquid optically clear adhesive that fills the second gap; and an edge seal having a width w_e and a height h_e, being made of a thermoplastic material, disposed in between said first and second glass layers and applied around the perimeter of the glazing.

The edges of the active insert are normally hidden from view from the interior or exterior of the vehicle by an obscuration typically applied to surface two, 102, of the first glass layer, 201, and surface four, 104, of the second glass layer, 202. Therefore at least one obscuration layer may be disposed onto the perimeter of the interior surface of the first glass layer and/or disposed onto the perimeter of either the interior or exterior surfaces of the second glass layer and having a width Wo such that w₀ is greater than w_e. Additionally, the one or more obscuration layers may be comprised of one of the following: an opaque plastic layer, and a black enamel frit or an organic ink printed onto either or both of the glass layers. Preferably obscurations may have a light transmission of below 5 %.

The width of the obscuration is sufficient to hide at least the edge seal, and preferably also the dam and the portions of the active insert that are not intended to be visible. This includes any electrical connection points. In a preferred embodiment the edge seal is applied around substantially the entire perimeter of the glazing. The standard lamination process used to fabricate automotive laminates makes use of heat and pressure to bond the glass layers to the polymer interlayer and to render the interlayer optically transparent. This standard process is known as hot lamination.

When the laminate layers are bonded by means of a liquid optically clear adhesive (LOCA), elevated temperatures and pressures are not used. This is called cold lamination.

With the method of the invention, a hybrid lamination process is used. A combination of both hot and cold lamination methods is used. This enables the lamination of inserts, including heat, pressure or vacuum sensitive inserts that would not otherwise be practical or even possible to fabricate with traditional lamination materials and processes alone.

A laminate fabricated with just a LOCA bonding together with the glass layers is not likely to be able to pass regulatory requirements for penetration resistance or be able to provide the level of ultraviolet (UV) light protection needed. In the first part of the method, the hot lamination process is used to bond an interlayer to a glass layer forming a pre-assembly. In the pre-assembly, in one preferred embodiment the first plastic interlayer is in contact with the first glass layer. This pre-assembly provides the penetration resistance and UV protection needed. UV protection can be guaranteed by either a UV performance interlayer or by using a first glass layer having UV protection. Preferably the UV protection required by the variable light transmission inserts is a light transmission of less than 20%, and preferably less than 5% in the wavelength range of 280 nm to 410 nm.

The pre-assembly is then laminated to the insert using a cold lamination process which allows for the use of inserts that are not practical or possible to laminate by hot lamination methods alone.

Many of the proposed and current inserts will be damaged or destroyed by the heat and pressure of the autoclave. The inserts may also be damaged or destroyed by the vacuum that is typically needed to remove the air from the layers when an insert is used between two plastic interlayers.

Some types of inserts are also sensitive to UV and will not survive long-term exposure without degradation and eventual failure. Standard PVB contains UV blockers. Specially formulated PVB is also available with enhanced UV protection that blocks substantially all UV light spectrum as well as light in the near UV. This UV enhanced PVB was developed specificallyfor use with certain types of VLT films. On the other hand, LOCAs do not typically contain UV blockers, especially those that cure and cross-link by means of UV exposure.

To meet these challenges an innovative hybrid lamination method has been developed that combines the benefits of both a hot lamination with a UV blocking interlayer and cold lamination with a LOCA.

The interlayer 4 is laminated to surface two, 102, of the first glass layer, 201. This is the hot lamination portion of the method and is very similar to the method used for standard laminates. The process is illustrated in Figures 4A and 4B. The plastic interlayer 4 is comprised of any of the following polyvinyl butyral (PVB), ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), polyolefin elastomers (PoE), or a combination thereof.

The plastic interlayer 4 is placed between the two bent glass layers 201, 202 as is done with a typical laminated glazing. Alternately, rather than using the second glass layer 202, a reusable mold may be used in its place. A separator such as a non-adhesive plastic interlayer 30 is placed between the plastic interlayer 4 and surface three, 103, of the second glass layer, 202. The separator 30 is made of a material that will not stick to the glass or reusable mold and that the plastic interlayer 4 may be desired not to stick too. This first pre-assembly of first glass layer, separator layer (optional), and first plastic interlayer (Figure 4A) is processed through a typical autoclave lamination cycle with heat and pressure.

The method for making the first pre-assembly is as follows: providing a first glass layer having an exterior surface oriented towards the outside of the laminated glazing, and an interior surface oriented towards the inside of the laminated glazing; placing a first plastic interlayer on the interior surface of the first glass layer; placing a separator layer on the surface of the first plastic interlayer, which is not in contact with the first glass layer; providing a reusable mold or a second glass layer having an exterior surface oriented towards the outside of the laminated glazing, and an interior surface oriented towards the inside of the laminated glazing; placing a mold or the interior surface of the second glass layer onto the surface of the separator layer not in contact with said first plastic interlayer, and laminating with heat and pressure;

After lamination, the first glass layer 201 with the first plastic interlayer bonded to it, the separator, and the second glass layer 202 or mold are separated (Figure 4B). A mold, reusable or not, can be used in place of the second glass layer. The intent is to allow for lamination of the first glass layer with the first plastic interlayer. The assembly of the outer glass 201 and the first glass layer interlayer, with optionally the separator 30, forms the first pre-assembly 32. Examples of suitable separator layers are PET, COP, PC, PS, PE, PMMA, and the combination of thereof. The separator 30 may be discarded or reused depending upon its construction. The separator 30 may also be left in the first pre-assembly. In the case where the separator layer is not removed, then the first pre-assembly is comprised of a separator layer arranged in between the first plastic interlayer and the active film such that the first dam is arranged in between said separator layer and the active film forming the first a gap.

The first dam is made of a thermoplastic material. Advantageously the glass layers 201 and 202 could be curved or flat. Optionally, the second glass layer 202 could also have a plastic interlayer 4, referred to a second plastic interlayer bonded to it and forming a second pre-assembly. This is illustrated by Figure 4C. In this case, the method is further comprised by the following: providing a second plastic interlayer; providing and placing the second plastic interlayer on the interior surface of the second glass layer; placing the second glass layer with the second plastic interlayer together with the first pre-assembly such that the first separator layer is disposed in between the first and the second plastic interlayer, and laminating with heat and pressure; separating the first pre-assembly, which is comprised of the first glass layer with the first plastic interlayer, from the second pre-assembly, which comprises the second glass layer with the second plastic interlayer; and optionally removing the first separator layer from the first pre-assembly.

The first pre-assembly 32 is then used as the base for the cold lamination steps. The cold lamination method follows the steps below: arranging an active film onto the surface of either the separator layer or first plastic interlayer of the first pre-assembly, wherein the active film is spaced from said separator layer or first plastic interlayer by first dam such that a first gap is formed; filling the first gap in between either the separator layer or the first plastic interlayer, and the active film with a first curable liquid optically clear adhesive; placing a frame-like edge seal made of a thermoplastic material on the perimeter of either the first plastic interlayer, isolator layer, or the second glass layer; joining the second glass layer, the edge seal, and the first pre-assembly such as to form a second gap in between the second glass layer and the active film, and heating said edge seal to a temperature that promotes bonding of the edge seal to the adjacent layers; filling the second gap in between the active film and the second glass layer with a second curable liquid optically clear adhesive; and curing the first and the second curable liquid optically clear adhesive independently or simultaneously.

Figure 5A illustrates applying of the first dam 26, and bond the insert 24 to the first dam 26 is illustrated by Figure 5B. The volume enclosed between the insert 24, the first dam 26, and the pre-assembly 32, is filled the volume with a first LOCA 20, forming a first assembly, as shown in Figure 5C. Subsequently a second dam 28, is applied to a second glass layer 202 and the second glass layer is joined to the first assembly such that the second dam 28 is in between the second glass 202 and the pre-assembly 32 as shown in Figure 6A. The volume enclosed between the second glass, the second dam 28 and the prelaminated 32 is filled with a second LOCA, as shown in Figure 6B. The first and second LOCAs are cured by any adequate means. Finally, an edge seal 16 is dispensed and cured in the periphery of the glazing arranged such as to protect the dams, the LOCAs and the insert illustrated in Figure 7A. The temperature necessary to promote bonding of the edge seal to the adjacent layers can vary from at least 60 °C, more preferably at least 80 °C.

In another embodiment of this invention after arranging the active film spaced from the first plastic interlayer, a second dam is placed in between the second glass layer interior surface and the active film surface that does not face the first plastic interlayer, wherein the second dam contains and seals the second curable optically clear adhesive layer. This steps are illustrated in Figures 9A and 9B leading to the final product 7B. The isometric exploded view of this embodiment is illustrated in Figure 2. Figure 3 is a top view of the laminated roof of Figure 2. The second dam is made of a thermoplastic material.

The laminated glazing of the invention may further comprise a second plastic interlayer disposed onto the second glass layer, similarly illustrated by Figures 10A and 10B, which are equivalent to Figures 7A and 7B, however comprising the second plastic interlayer.

Advantageously the laminated glazing of the invention may further comprise of a low emissivity and/or anti-reflective coating applied to the exterior surface of the second glass layer.

The steps will be described in detail in the examples and embodiments that follow.

EXAMPLES:

Example 1

Example one is the hybrid laminated roof with edge seal aspects of which are shown in Figures 2, 3, 4A, 4B, 5A, 5B, 5C, 6A, 6B and 7A.

The inner 202 glass layer is comprised of 2.3 mm clear soda-lime glass. The outer 201 glass layer is 2.6 mm dark solar green soda-lime glass.

The overall dimension of the roof is 800 mm by 1200 mm. A black frit obscuration 6 is screen printed on surface two, 102. Surface four, 104 of the inner glass layer 202 is printed with a pattern that has voids in the print totaling 10% of the printed area to allow for the UV LOCA to cure. The width of the obscuration is 100 mm.

An MSVD solar control coating is applied to surface two, 102 of the outer glass 201 layer. An MSVD low-e coating is applied to surface four, 104 of the inner glass layer.

The two glass layers are bent and allowed to cool. The outer glass layer 201 and a sheet of 1 mm thick enhanced UV block PVB are assembled and proceed as previously described to form the prelaminated 32.

The cold lamination steps of the method are shown in Figures 5A, 5B, 5C, 6A, 6B and 7A.

The first pre-assembly 32 is positioned with surface two 102 facing up. A first dam 26 is applied to the interlayer 4 (Figure 5A).

A number of materials and methods may be used to form the dam. A semi-viscous fluid may be extruded to form the first dam 26 and the second dam 28. The dam may comprise a solid that is bonded to the interlayer 4. The material used is compatible with the LOCA, interlayer and the insert.

Due to the excessive cost and difficulty in forming of some inserts, the size of the insert is kept at the minimum needed to cover the desired portion of the glazing while allowing for good aesthetics. This is generally just outboard of the inboard edge of the black obscuration. Some additional material is needed to account for the tolerance stack. Some also need to be allocated so as to allow the insert to be bonded to the dam which is required to contain the LOCA during the filling step. The insert may at least partially overlap substantially the periphery of the dam and be bonded to it. In a preferred embodiment the insert may at least partially overlap substantially the entire periphery of the dam and be bonded. Some voids may be intentionally made in the dam to create ports for the injection of LOCA and evacuation of air as well as for electrical connections. The placement of the dam will depend upon the cut size of the insert. The dam is placed sufficiently inboard of the edge of glass to provide space for the edge seal required. The edge seal width is typically at least 1 mm wide, preferably 3 mm wide. More preferably the edge seal is above 5 mm. Generally, this is in the 6 mm - 12 mm range. It could also be advantageous to have an edge seal of at least 10 mm wide. The edge seal could also be as wide as 500 mm. The width of the dam will depend upon the type of material used. The height (thickness) of the edge seal is at least 0.30 mm, preferably at least 0.70 mm to account for the thicknesses of the active film and the liquid optically clear adhesive layers. Preferably the height or thickness is no more than 2.30 mm, and preferably no more than 6.00 mm. The thickness of the dam will generally be at least that of a standard automotive interlayer, such as 0.70 mm but can be greater or less. The thickness of the dam will determine the thickness of the LOCA layer. The first dam of this example has a width of 12 mm and a thickness of 1 mm. A thermoform plastic is extruded onto the PVB interlayer side of the pre-assembly 32. The elevated temperature of the extruded material partially melts the PVB and bonds to it.

The active insert 24 is a sheet of SPD VLT with a thickness of 250 pm, as shown in the figures. The insert is cut to 25 mm larger than the inboard edge of the obscuration and formed to the curvature of the glass surface. Bus bars and connectors are applied.

During the assembly and placement of the insert 24 to the dam 26 an installation tool is used to support and hold the insert and to maintain its shape. This is needed to maintain a uniform LOCA thickness. The insert is affixed to a full surface positive tool and held in place by means of a vacuum.

The insert 24 is bonded by means of an adhesive (not shown) to the first dam 26 enclosing a volume bounded by the inboard side of the first dam 26, the inboard surface of the pre-assembly 32 and the dam 26 side surface of the insert 24 (Figure 5B).

This enclosed volume is filled with a LOCA creating the first LOCA 20 layer (Figure 5C). The first LOCA layer 20 may be cured at this point or later after the other second LOCA layer 22 is added. Next, the second dam 28 is applied to the second glass layer 202 and it all is joined and bonded to the first assembly. (Figure 6A). The second dam is 12 mm wide and 2.5 mm thick. The second dam has an outboard edge that is 12 mm inboard from the edge of the second glass layer 202 so as to allow space for the edge seal 16.

The volume enclosed by the second glass 202, the second dam 28, the insert 24, and the preassembly 32 is then filled with a second LOCA 20 (Figure 6B).

The LOCA layers are allowed to cure.

Next, the edge is sealed by an edge seal 16. Surprisingly, it has been found that ordinary automotive interlayers, which already meet the criteria for glass adhesion and durability, are compatible with most dam materials and LOCAs and also provide an adequate moisture resistant edge seal. PVB, EVA, TPU, PoE, ionomer, and acrylic are examples of suitable materials chosen for the edge seal. In this particular example, PVB is used to fill the gap between the glass layers extending from the dam to the edge of glass. In this example, the PVB is heated into its glass transition range and extruded. The cross section of the resulting laminate is shown in Figure 7A. Example 2

Example two, a hybrid laminated roof with edge seal, is similar to example one in most respects. The pre-assembly is formed in the same hot lamination method as in the example one. The cold lamination steps of the method are shown in Figures 8A, 8B, 8C, 9A, 9B and 7B.

The first dam 26 of this example has a width of 12 mm and a thickness of 1 mm. The outboard edge of the dam is located 12 mm inboard of the edge of glass.

A thermoform plastic is extruded onto the PVB interlayer side of the pre-assembly 32 (Figure 8A). The elevated temperature of the extruded material partially melts the PVB and bonds to it. The active insert 24 is a sheet of SPD VLT with a thickness of 250 pm, as shown in the figures. The insert is cut to 20 mm smaller than the outboard edge of the glass and formed to the curvature of the glass surface. Bus bars and connectors are applied. This is done to obscure forming defects in the insert that tend to occur near the edges. With a 100 mm wide black obscuration 6, nominally, 80 mm of the insert will be hidden. Figures are exaggerated and do not follow the exact measurements with the intend to only illustrate the main aspects of the invention.

During the assembly and placement of the insert 24 to the dam 26 a tool is used to hold the insert and to maintain its shape. This is needed to maintain a uniform LOCA thickness. The insert is affixed to a full surface positive tool and held in place by means of a vacuum.

The insert 24 is bonded by means of an adhesive (not shown in the figure) to the first dam 26 enclosing a volume bounded by the inboard side of the first dam 24, the inboard surface of the pre-assembly 32 and the dam 26 side surface of the insert (Figure 8B).

This enclosed volume is filled with a LOCA creating the first LOCA 20 layer (Figure 8C). The first LOCA layer 20 may be cured at this point or later after the other second LOCA layer 22 is added. Next, the second dam 28 is applied to the second glass layer 202 and it is joined to the first assembly (Figure 9A). The second dam is 12 mm wide and 2.5 mm thick. The dam has an outboard edge that is 12 mm inboard from the edge of glass so as to allow space for the edge seal 16. The second dam 28 is located directly over the first dam 26.

The volume enclosed by the second glass layer 202, the second dam 28, and the insert 24 is then filled with a second LOCA 22 (Figure 9B).

The LOCA layers are allowed to cure.

Next, the edge is sealed 16. In this example, the PVB is heated into its glass transition range and extruded. The cross section of the resulting laminate is shown in Figure 7B. Similarly, Figure 10B illustrates a glazing of this invention further comprising a second plastic interlayer disposed onto the second glass layer.

EMBODIMENTS:

1. Embodiment one is the laminated glazing of example one wherein the active insert is any of the following: a LC VLT film, a PDLC VLT film, PNLC VLT film or an electrochromic VLT film.

2. Embodiment two is the laminated glazing of example two wherein the active insert is any of the following: a LC VLT film, a PDLC VLT film, PNLC VLT film, or an electrochromic VLT film.

3. Embodiment three is the laminated glazing of example one wherein the active insert comprises an LED lighting circuit adhered to transparent PET.

4. Embodiment four is the laminated glazing of example two wherein the active insert comprises an LED lighting circuit adhered to transparent PET, and a touch sensor .

5. Embodiment five is the laminated glazing of examples one or two wherein instead of an active insert, the glazing comprises an inactive insert such as a holographic film or projection film.

6. Embodiment six is the laminated glazing of examples one or two wherein instead of PVB, the edge seal 16 is made of one of the following ethylene vinyl acetate, thermoplastic polyurethane, polyolefin elastomer, ionomer, or acrylic.

Claims

CLAIMS A laminated glazing, comprising: a first glass layer having an exterior surface oriented towards the outside of the laminated glazing, and an interior surface oriented towards the inside of the laminated glazing; an active film, having a length Lf, a width Wf, and edges, wherein the length Lf is smaller than the length Li, and the width Wf is smaller than the width wi; a first plastic interlayer having a length L, a width w; and edges, being arranged in between the active film and the interior surface of the first glass layer; a first dam arranged between said first plastic interlayer and the active film, the first dam being arranged to form a first gap between the first plastic interlayer and the active film; a first curable liquid optically clear adhesive that fills the first gap; a second glass layer having an interior surface oriented towards the inside of the laminated glazing, an exterior surface oriented towards the outside of the laminated glazing, and being disposed such as to form a second gap between the second glass layer interior surface and the active film surface that does not face the first plastic interlayer; a second curable liquid optically clear adhesive that fills the second gap; and an edge seal having a width w_e and a height h_e, being made of a thermoplastic material, disposed in between said first and second glass layers and applied around the perimeter of the glazing. The laminated glazing of the preceding claim, further comprising a separator layer arranged in between the first plastic interlayer and the active film such that the first dam is arranged in between said separator layer and the active film forming the first a gap, and wherein said separator layer(s) is/are selected from PET, COP, PC, PS, PE, PM MA, and a combination thereof. The laminated glazing of any of the preceding claims, wherein the edge seal is selected from polyvinyl butyral, ethylene vinyl acetate, thermoplastic polyurethane, polyolefin elastomer, ionomer, and acrylic. The laminated glazing of any of the preceding claims, wherein the width w_e of the edge seal material is at least 1 mm wide, preferably 3 mm wide, and more preferably above 5 mm wide. The laminated glazing of any of the preceding claims, wherein the height h_e of the edge seal material is at least 0.30 mm and no more than 6.00 mm, preferably at least 0.70 mm, and no more than 2.30 mm. The laminated glazing of any of the preceding claims, wherein the first plastic interlayer provides ultraviolet light protection with a light transmission of less than 20 %, and preferably less than 5 % in the wavelength range of 280 nm to 410 nm. The laminated glazing of any one of the preceding claims, wherein the active insert is selected from the following group: an SPD film, a PDLC film, an LC film, an electrochromic film, a PNLC film, and the combination thereof. The laminated glazing of any one of the preceding claims, further comprises at least one lighting means and/or a touch sensor. The laminated glazing of any of the preceding claims, further comprises at least one obscuration layer disposed onto the perimeter of the interior surface of the first glass layer and/or disposed onto the perimeter of either the interior or exterior surfaces of the second glass layer and having a width w₀ such that w₀ is greater than w_e. The laminated glazing of the preceding claim, wherein the obscuration layer is comprised of one of the following: an opaque plastic layer, and a black enamel frit or an organic ink printed onto either or both of the glass layers. The laminated glazing of any of the preceding claims, wherein said first and second curable liquid optically clear adhesive layers are selected from the group of epoxy-based adhesive, acrylic-based adhesive, silicone-based adhesive, urethane-based adhesive, and a combination thereof. The laminated glazing of any of the preceding claims, wherein the first and the second curable liquid optically clear adhesive layers have different chemical compositions. The laminated glazing of any of the preceding claims, wherein the second curable liquid optically clear adhesive layer has a higher adhesion to the glass in comparison to the first curable liquid optically clear adhesive layer. The laminated glazing of any of the preceding claims, further comprises an infrared reflecting film layer or coating positioned or applied either onto the first or the second glass layers. The laminated glazing of any of the preceding claims, further comprises a low emissivity and/or an antireflective coating disposed onto the exterior surface of the second glass layer. The laminated glazing of any of the preceding claims, wherein any of the first and the second glass layers are selected from the group of soda lime, aluminosilicate, and borosilicate glass. The laminated glazing of any of the preceding claims, further comprises a second plastic interlayer disposed onto the interior surface of the second glass layer, such that instead the second gap is formed between the second plastic interlayer and the active film surface that does not face the first plastic interlayer. The laminated glazing of any of the preceding claims, wherein the first and the second plastic interlayers are selected from the group of PVB, EVA, TPU, POE, and the combination thereof. The laminated glazing of any of the preceding claims, further comprises a second dam located in between the first plastic interlayer layer, or the separator layer, and either the second glass layer, or the second plastic interlayer, wherein said second dam contains and seals the second curable optically clear adhesive layer. The laminated glazing of any of claims 1 to 18, further comprises a second dam located in between the active film surface that does not face the first plastic interlayer and either the second glass layer, or the second plastic interlayer, or the separator layer, wherein said second dam contains and seals the second curable optically clear adhesive layer. The laminated glazing of any of the preceding claims, wherein the first and/or the second dam(s) is/are made of a thermoplastic material. A vehicle roof or vehicle window comprising a laminated glazing according to any one of the preceding claims. A method for manufacturing a laminated glazing according to any of claims 1 to 21, comprising the following steps: providing a first glass layer having an exterior surface oriented towards the outside of the laminated glazing, and an interior surface oriented towards the inside of the laminated glazing; placing a first plastic interlayer on the interior surface of the first glass layer; placing a separator layer on the surface of the first plastic interlayer, which is not in contact with the first glass layer; providing a second glass layer having an exterior surface oriented towards the outside of the laminated glazing, and an interior surface oriented towards the inside of the laminated glazing; placing a mold or the interior surface of the second glass layer onto the surface of the separator layer surface which is not in contact with said first plastic interlayer, and laminating with heat and pressure; removing the mold or the second glass layer, and forming a first pre-assembly comprising the first glass layer, the first plastic interlayer and optionally the separator layer; arranging an active film onto the surface of either the separator layer or the first plastic interlayer of the first pre-assembly, wherein the active film is spaced from said separator layer or first plastic interlayer by a first dam such that a first gap is formed; filling the first gap in between either the separator layer or the first plastic interlayer and the active film with a first curable liquid optically clear adhesive; placing a frame-like edge seal made of a thermoplastic material on the perimeter of either the first plastic interlayer, isolator layer or the second glass layer; joining the second glass layer, the edge seal, and the first pre-assembly such as to form a second gap in between the second glass layer and the active film, and heating said edge seal to a temperature that promotes bonding of the edge seal to the adjacent layers; filling the second gap in between the active film and the second glass layer with a second curable liquid optically clear adhesive; and curing the first and the second curable liquid optically clear adhesives independently or simultaneously. The method according to claim 23, wherein after the step of filling the first gap with a first curable liquid optically clear adhesive, a second dam is placed in between the second glass layer interior surface and the active film surface that does not face the first plastic interlayer, wherein the second dam contains and seals the second curable optically clear adhesive layer. The method according to claim 23, wherein after arranging the active, a second dam is placed in between either the first plastic interlayer, or the separator layer, and the second glass layer, wherein the second dam contains and seals the second curable optically clear adhesive layer. The method according to any of claims 23 to 25, wherein the edge seal is a solid frame-like seal selected from polyvinyl butyral, ethylene vinyl acetate, thermoplastic polyurethane, polyolefin elastomer, ionomer, or acrylic, that when heated bonds to the adjacent layers. The method according to any of claims 23 to 26, wherein the edge seal is extruded onto the periphery of the glazing forming a frame-like seal. The method according to any of claims 23 to 27, wherein the curing steps are performed by any of the following processes: UV light curing, platinum curing, moisture curing, thermal curing, catalyst curing, room temperature curing, or a combination thereof. The method according to any of claims 23 to 28, wherein the second glass layer comprises a second pre-assembly formed by the following steps: providing a second plastic interlayer; providing and placing the second plastic interlayer on the interior surface of the second glass layer; placing the second glass layer with the second plastic interlayer together with the first pre-assembly such that the first separator layer is disposed in between the first and the second plastic interlayers, and laminating with heat and pressure; separating the first pre-assembly, which is comprised of the first glass layer with the first plastic interlayer, from the second pre-assembly, which comprises the second glass layer with the second plastic interlayer; and optionally removing the first separator layer from the first pre-assembly.