Method for manufacturing plastic window and plastic window

Patent metadata

Field	Value
Publication number	US-2017367149-A1
Application number	US-201715622465-A
Country	US
Kind code	A1
Filing date	Jun 14, 2017
Priority date	Jun 15, 2016
Publication date	Dec 21, 2017
Grant date	—

Abstract

A method for manufacturing a plastic window includes a mold preparation step for preparing a first mold, a second mold, and a third mold, a film preparation step for preparing a functional film, a conductive portion, and a bus bar, a placement step for placing the functional film, a first injection step, wherein an intermediate product provided with the cover on the functional film in an integral manner is made, and a second injection step, wherein a product provided with the intermediate product on the second surface in an integral manner is made. The first mold surface has a first forming portion forming the back surface of the cover and a second forming portion forming the second surface of the transparent body. In the placement step, the conductive portion is placed on the second forming portion and the bus bar is placed on the first forming portion.

First claim

What is claimed is:

1 . A method for manufacturing a plastic window, comprising:
a mold preparation step for preparing a first mold having a first mold surface, a second mold having a second mold surface and being closed with the first mold to form a first cavity between the first mold surface and the second mold surface, and a third mold having a third mold surface and being closed with the first mold to form a second cavity having a product shape between the first mold surface and the third mold surface; a film preparation step for preparing a functional film having a transparent base of a sheet shape, a conductive portion formed on a back surface of the base, and a bus bar formed on the back surface of the base and electrically connectable to the conductive portion, the functional film being thermally deformable; a placement step for placing the functional film on the first mold surface with the back surface of the base in contact with the first mold surface; a first injection step, wherein the first mold and the second mold are closed, wherein a first molten resin is injected into the first cavity to form a cover made of solidified opaque resin of the first molten resin, and wherein an intermediate product provided with the cover on a peripheral edge portion of the functional film in an integral manner is made; and a second injection step, wherein the first mold and the second mold are opened, wherein the first mold and the third mold are closed, wherein a second molten resin is injected into the second cavity to form a transparent body made of solidified transparent resin of the second molten resin and having a first surface and a second surface located on an opposite side from the first surface, and wherein a product provided with the intermediate product on a peripheral edge portion of the second surface in an integral manner is made, wherein the first mold surface has a first forming portion forming the back surface of the cover and a second forming portion forming the second surface of the transparent body, and wherein in the placement step, the conductive portion is placed on the second forming portion and the bus bar is placed on the first forming portion.

2 . A method for manufacturing a plastic window, comprising:
a mold preparation step for preparing a first mold having a first mold surface, a second mold having a second mold surface and being closed with the first mold to form a first cavity between the first mold surface and the second mold surface, and a third mold having a third mold surface and being closed with the first mold to form a second cavity having a product shape between the first mold surface and the third mold surface; a film preparation step for preparing a functional film having a transparent base of a sheet shape, a conductive portion formed on a back surface of the base, and a bus bar forming portion formed on the back surface of the base for forming a bus bar electrically connectable to the conductive portion, the functional film being thermally deformable; a placement step for placing the functional film on the first mold surface with the back surface of the base in contact with the first mold surface; a first injection step, wherein the first mold and the second mold are closed, wherein a first molten resin is injected into the first cavity to form a cover made of solidified opaque resin of the first molten resin, and wherein a first intermediate product provided with the cover on a peripheral edge portion of the functional film in an integral manner is made; a second injection step, wherein the first mold and the second mold are opened, wherein the first mold and the third mold are closed, wherein a second molten resin is injected into the second cavity to form a transparent body made of solidified transparent resin of the second molten resin and having a first surface and a second surface located on an opposite side from the first surface, and wherein a second intermediate product provided with the first intermediate product on a peripheral edge portion of the second surface in an integral manner is made; and a bus bar forming step for forming the bus bar on the bus bar forming portion to produce a product, wherein the first mold surface has a first forming portion forming the back surface of the cover and a second forming portion forming the second surface of the transparent body, and wherein in the placement step, the conductive portion is placed on the second forming portion and the bus bar forming portion is placed on the first forming portion.

3 . A plastic window comprising:
a transparent body having a plate shape and including a first surface and a second surface located on an opposite side from the first surface, the transparent body being made of transparent resin; a cover provided on a peripheral edge portion of the second surface of the transparent body in an integral manner and being made of opaque resin; and a functional film provided on the second surface of the transparent body and a back surface of the cover in an integral manner, wherein the functional film comprises:
a transparent base having a sheet shape and being provided on the second surface of the transparent body and the back surface of the cover in an integral manner,
a conductive portion formed on the base and located on the second surface; and
a bus bar formed on the base and located on the back surface of the cover, the bus bar being electrically connectable to the conductive portion.

4 . A method for manufacturing a plastic window, comprising:
a mold preparation step for preparing a first mold having a first mold surface, a second mold having a second mold surface and being closed with the first mold to form a first cavity of a plate shape between the first mold surface and the second mold surface, and a third mold having a third mold surface and being closed with the second mold to form a second cavity having a product shape between the second mold surface and the third mold surface; a preparation step for preparing a functional film having a transparent base of a sheet shape, a conductive portion formed on a back surface of the base, a bus bar formed on the same side as the conductive portion with respect to the base and electrically connectable to the conductive portion, and a colored portion formed on a front surface of the base or the back surface of the base in an overlapping manner with the bus bar and made of opaque color to prevent the bus bar from being exposed to the front surface of the base, the functional film being thermally deformable; a placement step for placing the functional film on the first mold surface with the back surface of the base in contact with the first mold surface; a first injection step, wherein the first mold and the second mold are closed, wherein a first molten resin is injected into the first cavity to form a transparent body made of solidified transparent resin of the first molten resin and having a first surface and a second surface located on an opposite side from the first surface, and wherein an intermediate product provided with the transparent body on the front surface of the base of the functional film in an integral manner is made; and a second injection step, wherein the first mold and the second mold are opened, wherein the second mold and the third mold are closed, wherein a second molten resin is injected into the second cavity to form a cover made of solidified opaque resin of the second molten resin with the conductive portion and the bus bar being exposed outside the cover, and wherein a product provided with the cover on a peripheral edge portion of the second surface in an integral manner is made.

5 . A method for manufacturing a plastic window, comprising:
a mold preparation step for preparing a first mold having a f

Assignees

• Toyota Jidoshokki Kk

Inventors

• Takemura Kenji

Classifications

• B29K2995/0005

  Conductive · CPC title

• B29C45/14 Primary

  incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles {(B29C45/1671 takes precedence)} · CPC title

• B29K2069/00

  Use of PC, i.e. polycarbonates {or derivatives thereof}, as moulding material · CPC title

• B29K2995/0025

  Opaque · CPC title

• H05B3/86 Primary

  the heating conductors being embedded in the transparent or reflecting material {(H05B3/845 takes precedence)} · CPC title