WO2025125166A1

WO2025125166A1 - Window unit, mold, associated methods and use

Info

Publication number: WO2025125166A1
Application number: PCT/EP2024/085288
Authority: WO
Inventors: Frank BEKAERT; Jiri SKALA
Original assignee: AGC Glass Europe SA
Current assignee: AGC Glass Europe SA
Priority date: 2023-12-14
Filing date: 2024-12-09
Publication date: 2025-06-19
Anticipated expiration: 2026-06-14

Abstract

The present invention discloses a window unit comprising a glazing panel and a frame. The frame has an opened U-like shape, comprising first arm, a second arm and a body, which encompasses the edge of the glazing panel on several peripheral sides. The frame comprises a primary part which is in the form of a hard component and injected on the glazing panel; the frame has an inner contour and an exterior contour. The first arm, the second arm and the body forming a single piece, the primary part comprises a first slot (51) between the first arm and the body, the primary part comprises a second slot (52) between the second arm and the body, each of the first slot and the second slot extends from the exterior contour to the direction of the inner contour. The present invention also related to a mold and associated methods and use.

Description

Window unit, mold, associated methods and use

Technical Field

[0001] The present invention relates to a window unit used as a window for motor vehicles and the like, comprising a glazing panel with a frame comprising a rigid material.

Background Art

[0002] The injection of a rigid material around a glazing panel can cause one of the major drawbacks is the presence of permanent force applied to the glazing panel. This effort is caused by the shrinkage related to the injection process of the rigid material on the glazing panel and especially when the rigid material is injected on the major part of peripheral sides of the glazing panel and due to the shrinkage of the rigid material during the cooling step of the process of making the window unit.

[0003] These forces cause deformations of the glazing panel and therefore of the window unit. It is a reason why it is not easy to obtain for this kind of unit a correct dimensioning meeting specifications requested by car manufacturers.

[0004] A solution is to take account of these induced deformations to define the shape and dimensions of the tools used for the production of the window unit and for the injection of the rigid material. However, this solution generally requires the manufacture of a prototype mold used to inject parts that are subsequently measured in order to determine the value of these deformations. After that, on the basis of these measurements, compensations to be integrated into the series tools are defined in order to obtain dimensionally correct pieces in production. These steps are nevertheless long and expensive.

[0005] Moreover, even if this compensation step makes it possible to obtain dimensionally acceptable window units, it does not remove mechanical stresses existing in the glazing panel related to the applied forces.

[0006] Another solution is to inject a frame in several parts meaning that the frame is composed of several injected elements. This solution reduces deformations but still produces some constraints on the glazing panel. [0007] The existence of these constraints can be managed into the window unit if the glazing panel has a high level of resistance to constraints such as tempered glass.

[0008] On the other hand, knows encapsulation methods does not allow to encapsulate laminated glass because they have a much lower mechanical strength limit than tempered glass and therefore this cannot resist to the encapsulation of a rigid material surrounding it in the long term.

Summary of invention

[0009] It is an object of the present invention to alleviate these problems, and to provide a window unit with a frame providing less constraint on the glazing panel while having a dimensionally acceptable shape.

[0010] According to a first aspect of the invention, the invention relates to an improved window unit comprising a glazing panel and a frame. The frame has a U-like shape comprising first arm, a second arm and a body. The frame encompasses the edge of the glazing panel on several peripheral sides, preferably three peripherical sides.

[0011] The frame comprises a primary part which is in the form of a hard component and injected on the glazing panel.

[0012] The frame has an inner contour and an exterior contour; the inner contour been the closest to the centre of the window unit while the exterior contour is the furthest from the centre of the window unit.

[0013] In the sense of the invention, the centre of the glazing panel is the zone around the geometric centre of the glazing panel.

[0014] The solution as defined in the first aspect of the present invention is based on the primary part comprises a first slot between the first arm and the body.

[0015] The solution as defined in the first aspect of the present invention is also based on the primary part comprises a second slot between the second arm and the body.

[0016] Each of the first slot and the second slot extends from the exterior contour to the direction of the inner contour. [0017] According to a second aspect of the invention, the invention relates to a mold to inject a hard component onto a glazing panel to form the frame to produce a window unit according to the first aspect. The mold has a part to create said first and second slots on the frame

[0018] According to a third aspect of the invention, the invention relates also to a method to produce a window unit according to a first aspect of the invention comprising a step to inject into a mold according to the second aspect, the hard material on the glazing panel to form the frame.

[0019] It is noted that the invention relates to all possible combinations of features recited in the claims and/or in the description.

[0020] The following description relates to an automotive window unit but it's understood that the invention may be applicable to others fields like architectural windows as for transportation or any field where a window unit according to the first aspect can be used.

Brief description of drawings

[0021] This and other aspects of the present invention will now be described in more detail, with reference to the appended drawings showing various exemplifying embodiments of the invention which are provided by way of illustration and not of limitation. The drawings are a schematic representation and not true to scale. The drawings do not restrict the invention in any way. More advantages will be explained with examples.

[0022] FIG. 1 is a schematic view of a window unit according to the present invention.

[0023] FIG. 2 is a schematic sectional view along AA’ of a window unit illustrated in FIG. 1.

[0024] FIG. 3 is a schematic view of a window unit according to an exemplifying embodiment of the present invention.

[0025] FIG. 4 is a schematic view of the portion Z of the window unit illustrated in FIG. 3.

[0026] FIG. 5 illustrates a method to produce a window unit according to the present invention. [0027] FIG. 6 illustrates a method to instal a window unit on a vehicle according to the present invention.

Description of embodiments

[0028] In this document to a specific embodiment and include various changes, equivalents, and I or replacements of a corresponding embodiment. The same reference numbers are used throughout the drawings to refer to the same or like parts.

[0029] As used herein, spatial or directional terms, such as "inner", "outer", "above", "below", "top", "bottom", and the like, relate to the invention as it is shown in the drawing figures. However, it is to be understood that the invention can assume various alternative orientations and, accordingly, such terms are not to be considered as limiting. Further, all numbers expressing dimensions, physical characteristics, processing parameters, quantities of ingredients, reaction conditions, and the like, used in the specification and claims are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical values set forth in the following specification and claims are approximations that can vary depending upon the desired properties sought to be obtained by the present invention. In the following description, unless otherwise specified, expression “substantially” mean to within 10%, preferably to within 5%.

[0030] Moreover, all ranges disclosed herein are to be understood to be inclusive of the beginning and ending range values and to encompass any and all subranges subsumed therein. For example, a stated range of "1 to 10" should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g. 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10. Further, as used herein, the terms "deposited over" or "provided over" mean deposited or provided on but not necessarily in surface contact with. For example, a coating "deposited over" a substrate does not preclude the presence of one or more other coating films of the same or different composition located between the deposited coating and the substrate. [0031] Where the term “comprising” is used in the present description and claims, it does not exclude other elements or steps. Where an indefinite or definite article is used when referring to a singular noun e.g. "a" or "an", "the", this includes a plural of that noun unless something else is specifically stated. In this document, "configured to (or set to)" may be interchangeably used in hardware and software with, for example, "appropriate to", "having a capability to", "changed to", "made to", "capable of", or "designed to" according to a situation. In any situation, an expression "device configured to do" may mean that the device "can do" together with another device or component.

[0032] Furthermore, the terms first, second and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequence, either temporally, spatially, in ranking or in any other manner. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein. When it is described that a constituent element (e.g., a first constituent element) is "(functionally or communicatively) coupled to" or is "connected to" another constituent element (e.g., a second constituent element), it should be understood that the constituent element may be directly connected to the another constituent element or may be connected to the another constituent element through another constituent element (e.g., a third constituent element).

[0033] In the following description, unless otherwise specified, expression “substantially" mean to within 10%, preferably to within 5%.

[0034] With reference to FIG. 1, a first embodiment of the present invention is described.

[0035] FIG. 1 shows a window unit 1 comprising a glazing panel 2 and a frame 3.

[0036] The window unit permits to close an opening on a vehicle. Preferably, a window unit according to the present invention can be used as a quaterlite window.

<Glazing panel> [0037] According to some embodiments, the glazing panel can be a flat or curved panel to fit with the design of the car. The glazing panel can be processed, ie annealed, tempered, ••• to respect with the specifications of security and anti-thief requirements. A heatable system, for example a coating or a network of wires, can be applied on the glazing panel to add a defrosting and/or a demisting function for example.

[0038] In some embodiments, the glazing panel can be a glass panel or made of plastic material such as PC.

[0039] In preferred embodiments, the glass panel comprises at least one glass sheet.

[0040] In some embodiments, due to reduction of induced deformations on the glazing panel, the glazing panel can be a laminated glass panel. The laminated glazing comprises glass sheets maintained by one or more interlayers positioned between glass sheets. The interlayers employed are typically polyvinyl butyral (PVB) or ethylene-vinyl acetate (EVA) for which the stiffness can be tuned. These interlayers keep the glass sheets bonded together even when broken in such a way that they prevent the glass from breaking up into large sharp pieces.

[0041] The glass sheet can be a clear glass or a coloured glass, tinted with a specific composition of the glass or by applying a coating or a plastic layer for example.

[0042] In the case of a laminated glass panel, it could be advantageous to have varying thicknesses of glass sheets to reduce weight and noise. Due to of induced deformations on the glazing panel, thin glass sheets with a thickness less than 1mm can be used without be bent or deformed. Thus, such thin glass sheet can keep the desired design.

[0043] The glazing panel can be manufactured by any know method as for its components.

[0044] Different kind of shapes and/or height can be used in a window unit to optimize the releasing effect, the reinforcement, the design and the manufacturing process.

<Frame>

[0045] As illustrated in FIG. 1 and FIG. 3, the frame 3 has a U-like shape. [0046] In the sense of the present invention, a U-like shape means an opened shaped and means that the glazing panel is not entirely encompassed by the frame. That also means that the glazing panel is not fully encompassed by the frame.

[0047] The U-like shape comprises first arm 31, a second arm 33 and a body 32.

[0048] It is understood in the sense of the present invention that he first arm, the second arm and the body forms a single piece meaning that the frame 3 is continue from the end of the first arm to the end of the second arm to form the U-like shape. Each of the body and arms encompassed a different edge of the glazing panel.

[0049] A defined angle between the body and the first arm exists to encompass two edges of the glazing panel and the corner between said edges.

[0050] A defined angle between the body and the second arm exists to encompass two edges of the glazing panel and the corner between said edges.

[0051] These defined angles depends on the design of the perimeter of the glazing panel.

[0052] The U-like shape frame encompasses the edge of the glazing panel on several peripheral sides.

[0053] As illustrated in FIG. 1 and FIG. 3, at least a part of an edge 21 of the glazing panel is not encompassed by the frame.

[0054] The frame has an inner contour 36 and an exterior contour 37. In the sense of the present invention, a contour is the generic lines defining the frame while the outlines takes into account at least the shape of the slots.

[0055] It is understood that the frame as a 3D frame profile to fulfill the requirements.

[0056] According to the invention, the frame comprises a primary part which is in the form of a hard component. The hard material is injected on the glazing panel, in other terms the glazing panel is overmolded with the hard component. In the sense of the present invention, “in the form of a hard component” means a component having a young modulus higher than 1000 MPa.

[0057] In some preferred embodiments, the hard component comprises fibres, beads or any other elements able to reinforced the material.

[0058] In a preferred embodiment, the hard component is a polypropylene based material and more preferably a polypropylene with fibres such as a PP 30GF. Other hard materials, with a young modulus higher than 1000 MPa, as polyamide, styrenic and others can be also used.

[0059] In one embodiment of the invention, the frame can comprise a secondary part which is in the form of soft component, placed at least partially over the primary part. The soft material has a young modulus lower than the hard component. The secondary part allows to thigh the window unit on the structure where it is fixed. Such structure can be a car body, a building,

[0060] The secondary part can be injected in a second step over at least partially the primary part. Preferably, the secondary part is a single part. In some embodiments, the secondary part can be locally in contact with the glazing panel to ensure the aesthetic and the tightness of the window unit.

[0061] In another embodiment, at least a portion of the secondary part is in contact with the glazing panel and preferably at least in contact with the glazing panel at the level of the at least one constraints releasing mean.

[0062] In a preferred embodiment, the soft component is a thermoplastic elastomer based material. Styrenic based and vulcanized thermoplastics elastomer are generally used. The soft component is in another embodiment a soft polyvinyl chloride.

[0063] In some preferred embodiments, the window unit 1 comprises a decorative trim 4 and wherein the frame comprises attaching means 34 designed to attach the decorative trim to the frame.

[0064] In some embodiments, the attaching means can be clips, hooks or any other means designed to attach an element over another.

[0065] In some preferred embodiments, the decorative trim comprises a part of the attaching means. For example, the decorative trim comprises male elements and the frame comprises the corresponding female elements.

[0066] The window unit can comprises fixing elements designed to fix the window unit to another element like a car body, a decorative object, a door frame, •••. In such embodiments, fixing elements are fixed on the frame within the primary part 102a. In one embodiment, fixing elements are overmolded with the primary part 102a. In another embodiment, fixing elements are injected with the primary part. Others fixing elements like a division bar can be used.

[0067] Coming back to FIG. 1, the primary part comprises a first slot 51 between the first arm and the body. The primary part also comprises a second slot 52 between the second arm and the body. Each of the first slot and the second slot extends from the exterior contour to the direction of the inner contour.

[0068] That means that, in the sense of the present invention, starting from the exterior contour the slot can represent an opening extending from the exterior contour to substantially the centre of the window unit.

[0069] FIG. 2 illustrates some preferred embodiments where the frame is substantially flushed with one of the main surface of the glazing panel. The frame is injected over the edge of the glazing panel and over a portion of the other main surface to form a L-like shape in a sectional view.

[0070] As illustrated in FIG. 2, FIG. 3 and FIG. 3, the frame can comprises a bead 38 extending along at least part of the inner contour to reinforce the frame.

[0071] The bead is similar to a local and elongated over-thickness.

[0072] FIG. 4 illustrates a detailed view of the embodiments of FIG. 3 at the Z location.

[0073] In FIG. 4, the first slot 51 has a length L measured substantially perpendicular to the inner contour meaning parallel to the measurement of the width of the frame.

[0074] In some preferred embodiments, the first slot can have a generic triangle shape with an opening angle A to compensate the warpage and the deformation by flexibility. The angle A is measured between lateral edges of the first slot. The angle A is preferably equal to or higher than 2° to keep resistance while having enough flexibility, more preferably is equal to or higher than 5° to optimize the resistance and the flexibility. The angle A between lateral edges of the first slot and the second slot is preferably equal to or lower than 15° to keep resistance while having enough flexibility, more preferably is equal to or lower than 10° to optimize the resistance and the flexibility.

[0075] In some preferred embodiments, the second slot can have a generic triangle shape with an opening angle A to compensate the warpage and the deformation by flexibility. The angle A is measured between lateral edges of the second slot. The angle A is preferably equal to or higher than 2° to keep resistance while having enough flexibility, more preferably is equal to or higher than 5° to optimize the resistance and the flexibility. The angle A between lateral edges of the second slot and the second slot is preferably equal to or lower than 15° to keep resistance while having enough flexibility, more preferably is equal to or lower than 10° to optimize the resistance and the flexibility.

[0076] The depth of the first slot and/or the second slot is preferably the local thickness of the primary part meaning that the slot extends over the whole thickness measured substantially perpendicular to the surface of the glazing panel at the measurement point.

[0077] The lateral edges of the first and/or second slot can be substantially vertical or with an inclined shape to reduce overflow issues in the mold during the manufacturing process of the frame.

[0078] In preferred embodiments, the first and the second arms have substantially the same length and width and the similar shape depending to the desire application.

[0079] In such preferred embodiments, the first and the second slots have substantially the same shape, length L and angle A.

[0080] The shape, the length, the angle and others elements of each of the slots depends on the specific application and desired design of the window unit.

[0081] In some preferred embodiments, to minimize the shrinkage, the first slot and/or the second slot has a length (L) equal to and higher than 80% of the width of the frame close to said slot, preferably equal to and higher than 90% of the width of the frame close to said slot.

[0082] In some preferred embodiments, the first slot and/or the second slot extends to the edge of the bead. Meaning that the slot is opened from the exterior contour to the border of the bead.

[0083] As illustrated in FIG. 1, FIG. 3 and FIG. 4, the slots create a difference between the exterior outline of the frame, taking into account the shape of the slots, and the exterior contour, not taking into account the slots, to form like an opening facing outwards, away from the centre of the glazing panel.

[0084] As the first and the second slots do not extend across the entire width of the frame, the slots are stopped before the inner contour.

[0085] In some other preferred embodiments, the first slot and/or the second slot extends into the bead to optimize the flexibility.

[0086] Preferably, the distance between the inner contour and the bottom of the slot can be between 1 mm and 8 mm

[0087] In some embodiments, as illustrated in FIG. 4, to optimize the flexibility while keeping the resistance, the frame can comprises a first notch 39 in front of the end of the first slot at the inner contour.

[0088] To optimize the flexibility while keeping the resistance, the frame can comprises a second notch 39 in front of the end of the second slot at the inner contour.

[0089] As illustrated in FIG. 3 and FIG. 4, the notch creates a difference between the inner outline of the frame, taking into account the shape of the notch, and the exterior contour, not taking into account the notch, to form like an opening facing outwards, away from the centre of the glazing panel. It is understand that the notch and the corresponding slot cannot be connected to each other. A part of the hard material has to be present between the notch and the correspond slot to maintain the frame as a single piece.

[0090] In one embodiment of the invention, the primary part is in direct contact with the glazing panel meaning that the primary part is injected on the glazing panel. The glazing panel can have locally a bonding agent or primer material to ensure tightness and/or to promote the encapsulation of the primary part on the glazing panel.

[0091] The present invention also related in a second aspect to a mold to create a window unit according to the first aspect.

[0092] Preferably, the mold comprises two parts that can be separated from each other. Each of the parts has at least one cavity having a specific shape.

[0093] Once the portion of the glazing panel to be overmolded is between these parts and the parts are closed, a specific volume is created around the glazing panel. The hard material is injected into this volume to create the frame. The mold comprises at least an element to create said first and second slots on the frame.

[0094] The element can be made directly with the cavity or can be inserted between the glazing panel and the cavity.

[0095] To produce a window unit as described and as illustrated in FIG. 5, the present invention relates to a method comprising following steps :

A. Providing 401 a glazing panel 2 produced separately;

B. Injecting 402, into a mold according to the second aspect, the hard material on the glazing panel to form the frame.

[0096] The method can further comprises a step 403 after the injection step 402 of attaching a decorative trim to the frame.

[0097] As illustrated in FIG. 6, the present invention also relates to a fourth aspect to a method to install a window unit according to the first aspect to a vehicle to close an opening on a vehicle.

[0098] Said method comprises a step of providing a window unit according to the first aspect and a step of installing said window unit in front of the opening to be closed.

[0099] The present invention relates also to the use of a first slot and a second slot of a frame to reduce the warpage and the deformation of a glazing panel of a window unit according to the first aspect of the invention.

Claims

Claim 1. A window unit (1) comprising a glazing panel (2) and a frame (3); the frame has an opened U-like shape, comprising first arm (31), a second arm (33) and a body (32), which encompasses the edge of the glazing panel on several peripheral sides; the frame comprises a primary part which is in the form of a hard component and injected on the glazing panel; the frame has an inner contour (36) and an exterior contour; characterized in that the first arm, the second arm and the body forming a single piece, in that the primary part comprises a first slot (51) between the first arm and the body, in that the primary part comprises a second slot (52) between the second arm and the body, in that each of the first slot and the second slot extends from the exterior contour to the direction of the inner contour.

Claim 2. A window unit according to claim 1, wherein the window unit comprises a decorative trim (4) and wherein the frame comprises attaching means (34) designed to attach the decorative trim to the frame.

Claim 3. A window unit according to any preceding claims, wherein the primary part is in direct contact with the glazing panel.

Claim 4. A window unit according to any preceding claims, wherein the glazing panel comprises a glass sheet.

Claim 5. A window unit according to any preceding claims, wherein the glazing panel is a laminated glass panel.

Claim 6. A window unit according to any preceding claims, wherein the angle between lateral edges of each of the first slot and the second slot is equal to or higher than 2° , preferably is equal to or higher than 5° .

Claim 7. A window unit according to any preceding claims, wherein the angle (A) between lateral edges of each of the first slot and the second slot is equal to or lower than 15° , preferably is equal to or lower than 10° .

Claim 8. A window unit according to any preceding claims, wherein the first slot and/or the second slot has a length (L) equal to and higher than 80% of the width of the frame close to said slot, preferably equal to and higher than 90% of the width of the frame close to said slot.

Claim 9. A window unit according to any preceding claims, wherein the frame comprises a bead (38) extending along at least part of the inner contour.

Claim 10. A window unit according to claim 9, wherein each of the first slot and the second slot extends to the edge of the bead.

Claim 11. A window unit according to claim 9, wherein each of the first slot and the second slot extends into the bead.

Claim 12. A window unit according to any preceding claims, wherein the frame comprises at the inner contour a first notch (39) in front of the end of the first slot and wherein the frame comprises at the inner contour a second notch in front of the end of the second slot.

Claim 13. A window unit (1) according to any preceding claims, wherein the hard component is a polypropylene based material.

Claim 14. Mold to produce a window unit (1) according to claims 1 to 13, comprising at least an element to create said first and second slots on the frame.

Claim 15. Method to produce a window unit (1) according to claims 1 to 13, the method comprises following steps :

A. Providing (401) a glazing panel (2);

B. Injecting (402), into a mold according to claim 14, the hard material on the glazing panel to form the frame.