Multi-layer structure suitable for use as a reflector

Patent metadata

Field	Value
Publication number	US-12313866-B2
Application number	US-202118039043-A
Country	US
Kind code	B2
Filing date	Nov 25, 2021
Priority date	Nov 30, 2020
Publication date	May 27, 2025
Grant date	May 27, 2025

Abstract

The invention relates to a filler-containing multi-layer structure on the basis of a polycarbonate composition, having a metal layer as a reflective layer and having a balanced property profile of CLTE, CLTE ratio, heat conductivity and lustre. This multi-layer structure can be used, inter alia, for reflectors or as a mirror element in head-up displays. Expanded graphite and burned silicon dioxide are contained as fillers. In the composition provided according to the invention, there is no need for an additional heat sink when implementing the component.

First claim

The invention claimed is:

1. A layer structure, comprising
i) a substrate layer made of a thermoplastic polycarbonate-based composition and
ii) a metal layer applied to the substrate layer i, wherein
the thermoplastic polycarbonate-based composition of substrate layer i contains the following components:
a) 44% to 63% by weight of aromatic polycarbonate,
b) 3% to 8% by weight of expanded graphite,
c) 34% to 38% by weight of fused silica,
d) 0% to 10% by weight of one or more further additives,
wherein the total amount of expanded graphite and fused silica is at least 40% by weight.

2. The layer structure as claimed in claim 1 , wherein the thermoplastic polycarbonate-based composition of substrate layer i contains
a) 54% to 60% by weight of aromatic polycarbonate,
b) 5% to 7.5% by weight of expanded graphite,
c) 35% to 37.5% by weight of fused silica,
d) 0% to 5% by weight of one or more further additives.

3. The layer structure as claimed in claim 1 , wherein the substrate layer has been produced by injection molding with dynamic temperature control of a mold.

4. The layer structure as claimed in claim 1 , wherein the layer structure comprises no further layers other than optionally one or more protective layers.

5. The layer structure as claimed in claim 1 , wherein the thermoplastic polycarbonate-based composition of substrate layer i consists of components a to c and optionally d.

6. The layer structure as claimed in claim 1 , wherein the group of the further additives consists of the group of flame retardants, heat stabilizers, antistats, UV absorbers, IR absorbers, anti-dripping agents, impact modifiers, antioxidants, inorganic pigments, carbon black, organic colorants, inorganic fillers and/or mold-release agents.

7. The layer structure as claimed in claim 1 , wherein a D(0.5) of the expanded graphite is 700 μm to 1200 μm, determined by sieve analysis in accordance with DIN 51938:2015-09.

8. The layer structure as claimed in claim 1 , wherein a D(0.5) of the fused silica is 2.5 μm to 8.0 μm, determined in accordance with ISO 13320:2009-10.

9. The layer structure as claimed in claim 1 , wherein D(0.5) of the fused silica is 3 μm to 5 μm, determined in accordance with ISO 13320:2009-10.

10. The layer structure as claimed in claim 1 , wherein for the substrate layer a ratio of a longitudinal and transversal CLTE value (longitudinal: transversal), determined in accordance with DIN 53752-Method A: 1980, is ≥0.84 and an in-plane thermal conductivity, determined in accordance with ASTM E 1461:2013, is >0.7 W/(m·K) and a Vicat temperature, determined in accordance with DIN ISO 306:2014-3, is ≥141° C. and a gloss, determined in accordance with ASTM D 523-14, is >90°.

11. The layer structure as claimed in claim 1 , wherein the metal layer ii has a thickness of ≥60 nm to ≤300 nm, determined by atomic force microscopy.

12. A component comprising a layer structure as claimed in claim 1 .

13. The component as claimed in claim 12 , wherein the component is a reflector or a mirror element of a head-up display.

14. The component as claimed in claim 13 , wherein the component is a headlamp reflector.

15. A method for producing a layer structure as claimed in claim 1 , wherein
a) the substrate layer is formed from the thermoplastic polycarbonate-based composition by one-component injection molding with dynamic temperature control of a mold and then
b) a metal layer is applied to this substrate layer.

Assignees

• Covestro Deutschland Ag

Inventors

• Hungerland Tim
• Protte Rainer

Classifications

• B60K35/23

  Head-up displays [HUD] (optical aspects of head-up displays G02B27/01) · CPC title

• B29K2995/0094

  Geometrical properties · CPC title

• B29K2995/0022

  Bright, glossy or shiny surface · CPC title

• B29K2995/0013

  Conductive · CPC title

• B29K2509/08

  Glass · CPC title