JP2017149380A - Resin rear window and resin window - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin rear window on which heat rays excellent in connectivity with wiring on a vehicle side are provided.SOLUTION: There is provided a resin rear window which includes a first resin base, a second resin base arranged so as to face the first resin base, heat rays arranged between the first resin base and the second resin base, a pad for power feeding connected to the heat rays and a flexible substrate having a terminal connected to the pad for power feeding, where one end of the flexible substrate is sandwiched between the first resin base and the second resin base so that the terminal is connected to the pad for power feeding, and the other end of the flexible substrate is exposed to the outside from the first resin base and the second resin base.SELECTED DRAWING: Figure 1

Description

The present invention relates to a resin rear window and a resin window.

The rear window for an automobile generates heat when energized to prevent or remove fogging generated on the glass.

As a structure for connecting the heat ray formed in the rear window for automobiles to the wiring on the vehicle side, for example, in Patent Document 1, a glass plate on which a heat ray print is formed as a connection portion, and provided on the glass plate, A window glass structure having a conductor electrically connected to the heat ray print and a lead wire electrically connected to the heat ray print and electrically connected to the conductor via the heat ray print is described. ing.

Patent Document 1 describes that a conductor provided on a glass plate and a lead wire connected to the conductor are electrically connected to each other by soldering to a hot wire print. Patent Document 1 describes that the glass plate may be a laminated glass in which a resin film and a conductor are sandwiched and bonded between two glasses.

JP2013-112122A

In recent years, the use of resin glass for automobile windows has been studied for the purpose of reducing the weight of automobiles.
However, when resin glass is used for an automobile rear window, how to provide heat rays to the resin rear window and how to connect the heat wires provided to the resin rear window to the wiring on the vehicle side Has not been fully studied.

For example, when the glass structure described in Patent Document 1 is applied to a resin rear window, polycarbonate or the like, which is a resin glass material, is a thermoplastic resin, so that there is a problem that the resin glass is deformed during soldering. There are concerns about the occurrence.

The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a resin rear window provided with a heat ray excellent in connectivity with wiring on the vehicle side. Another object of the present invention is to provide a resin window provided with a conductor excellent in connectivity with wiring on the vehicle side.

The resin rear window of the present invention is disposed between the first resin base, the second resin base disposed to face the first resin base, and the first resin base and the second resin base. And a flexible substrate including a terminal for connecting to the power supply pad, and one end of the flexible substrate is connected to the power supply pad. It is sandwiched between the first resin base and the second resin base so as to be connected, and the other end of the flexible substrate is exposed to the outside from the first resin base and the second resin base. It is characterized by that.

In the resin rear window of the present invention, a flexible substrate is sandwiched between two resin substrates, and the flexible substrate is connected to a power supply pad connected to a heat ray. Therefore, the heat wire provided in the resin rear window can be electrically connected to the vehicle-side wiring via the flexible substrate.

In the resin rear window of the present invention, since the flexible substrate is connected to the power feeding pad by being sandwiched between two resin bases, it is not necessary to connect the two using a special fixing tool. It is not necessary to bond the two using solder, conductive paste, or the like. Therefore, it is possible to prevent the problem that the resin substrate is deformed by the heat of soldering and the problem that the connectivity is deteriorated due to deterioration or migration of the conductive paste.

In the resin rear window of the present invention, the flexible substrate exposed to the outside from the two resin substrates has flexibility, so that operations such as folding and hooking are possible. Therefore, when the resin rear window of the present invention is assembled to the vehicle body, for example, an operation such as folding the flexible board and storing it in the hinge can be performed.

Moreover, in the resin rear window of the present invention, the heat rays are disposed between the two resin substrates, so that the heat generated by the heat rays is easily transmitted uniformly to both surfaces of the rear window. As a result, an anti-fogging effect without unevenness can be obtained.

Furthermore, in the resin rear window of the present invention, since the connecting portion between the flexible substrate and the power feeding pad is located between the two resin bases, the connecting portion is not easily damaged by vibration or the like. It is possible to prevent the problem that the connectivity is lowered.

In the resin rear window of the present invention, it is preferable that the first resin base and the second resin base are both made of polycarbonate or polymethyl methacrylate.
Since these resins have high translucency, do not have birefringence, and have sufficient strength, they can be suitably used as a resin substrate material.

In the resin rear window of the present invention, the flexible substrate is preferably made of polyimide.
Since polyimide is excellent in flexibility, it can be suitably used as a material for a flexible substrate.

In the resin rear window of the present invention, a Ni / Au plating layer is preferably provided on the surface of the power supply pad and the surface of the terminal of the flexible substrate.
By providing the Ni / Au plating layer on the surface of the power supply pad and the surface of the terminal of the flexible substrate, electrical connection between the power supply pad and the flexible substrate can be reliably performed.

In the resin rear window according to the present invention, the area of the main surface of the first resin base is larger than the area of the main surface of the second resin base, and the resin rear window is formed on the periphery of the resin rear window. It is preferable that a region thinner than the central portion exists.
Usually, the peripheral part of the rear window is an invisible part to which black coating for masking or the like is applied. Therefore, the rear window can be reduced in weight by making the peripheral part that does not affect the visibility during driving thinner than the central part.
Further, when the thickness of the central portion other than the peripheral portion is constant, a uniform anti-fogging effect can be obtained and the visibility during driving is excellent. Furthermore, unlike the case where the thickness is continuously reduced from the central portion toward the peripheral portion, if the thickness of the central portion is constant, the entire rear window can be prevented from becoming a lens shape. The problem of temperature unevenness due to penetration is less likely to occur.

In the resin rear window of the present invention, a primer layer is provided on at least one of the main surfaces of the first resin base and the second resin base opposite to the heat ray, and the primer layer It is preferable that a hard coat layer is provided thereon.
In this case, since the surface hardness can be increased, it is possible to provide a rear window in which scratches and the like are unlikely to occur on the surface.

The resin window of the present invention includes a resin base, a conductor disposed on or inside the resin base, a power supply pad connected to the conductor, and a terminal for connecting to the power supply pad. A flexible substrate, and one end of the flexible substrate is fixed to the resin base so that the terminal is connected to the power supply pad, and the other end of the flexible substrate is external to the resin base. It is exposed.

In the resin-made window of the present invention, the flexible substrate is fixed to the resin base, and the flexible substrate is connected to a power feeding pad connected to a conductor such as a heat ray. Therefore, the conductor provided in the resin-made window can be electrically connected to the wiring on the vehicle side through the flexible substrate.

In the resin window of the present invention, for example, a flexible substrate and a power supply pad can be connected using a conductive paste such as a silver paste. Therefore, it is possible to prevent the problem that the resin substrate is deformed by the heat of soldering.

In the resin-made window of the present invention, the flexible substrate exposed to the outside from the resin substrate has flexibility, so that operations such as folding and hooking are possible. Therefore, when the resin window of the present invention is assembled to the vehicle body, for example, an operation such as folding the flexible board and storing it in the hinge is possible.

Fig.1 (a) is a top view which shows typically an example of the resin-made rear windows of this invention, FIG.1 (b) is an expansion perspective view of the A section shown to Fig.1 (a), FIG. 1 (c) is a cross-sectional view taken along line BB in FIG. 1 (b). FIG. 2 is a plan view schematically showing another example of the resin rear window of the present invention. FIG. 3 is a plan view schematically showing still another example of the resin rear window of the present invention. FIG. 4 is an enlarged cross-sectional view schematically showing an example of the resin rear window of the present invention when a primer layer and a hard coat layer are provided. FIG. 5 is a plan view schematically showing an example of the resin window of the present invention.

(Detailed description of the invention)
[Resin rear window]
The resin rear window of the present invention is disposed between the first resin base, the second resin base disposed to face the first resin base, and the first resin base and the second resin base. And a flexible substrate including a terminal for connecting to the power supply pad, and one end of the flexible substrate is connected to the power supply pad. It is sandwiched between the first resin base and the second resin base so as to be connected, and the other end of the flexible substrate is exposed to the outside from the first resin base and the second resin base. It is characterized by that.

In the resin rear window of the present invention, the first resin base and the second resin base are arranged to face each other. It is preferable that the first resin substrate and the second resin substrate are pressure-bonded via an intermediate film provided therebetween. The intermediate film is preferably made of polyvinyl butyral (PVB). The thickness of the intermediate film is preferably 5 to 200 μm. The intermediate layer may be a single layer or two or more layers.

In the resin rear window of the present invention, a heat ray and a power supply pad connected to the heat ray are disposed between the first resin base and the second resin base. The power feeding pad is provided at the end of the heat wire and functions as a terminal electrode. It is preferable that the power supply pad is disposed at the peripheral portion of the resin rear window that becomes the invisible portion.

In the resin rear window of the present invention, the method of disposing the heat ray and the power supply pad between the first resin base and the second resin base is not particularly limited. And a method of forming a heat ray and a power supply pad on the inner surface of the resin substrate, and a method of interposing a film on which the heat ray and the power supply pad are formed between the intermediate film and the resin substrate. The heat ray and the power supply pad may be disposed between the intermediate film and the first resin substrate, or may be disposed between the intermediate film and the second resin substrate.

In the resin rear window of the present invention, the flexible board includes a terminal for connecting to the power supply pad, and one end of the flexible board including the terminal is sandwiched between the first resin base and the second resin base. Has been. That is, at one end of the flexible substrate, the terminal of the flexible substrate is connected to the power feeding pad.

On the other hand, the other end of the flexible substrate is exposed to the outside from the first resin base and the second resin base. The other end of the flexible substrate is electrically connected to an external power source.
Therefore, in the resin rear window of the present invention, a current flows through the heat wire through the flexible substrate and the power supply pad, and the heat wire generates heat.

Fig.1 (a) is a top view which shows typically an example of the resin-made rear windows of this invention, FIG.1 (b) is an expansion perspective view of the A section shown to Fig.1 (a), FIG. 1 (c) is a cross-sectional view taken along line BB in FIG. 1 (b).

A resin rear window 10 shown in FIGS. 1A, 1B, and 1C includes a first resin base 11 and a second resin base disposed so as to face the first resin base 11. 12, a heat wire 13 disposed between the first resin substrate 11 and the second resin substrate 12, a power supply pad 14 connected to the heat wire 13, and a terminal 15 a for connecting to the power supply pad 14. A flexible substrate 15. One end of the flexible substrate 15 is sandwiched between the first resin base 11 and the second resin base 12 so that the terminal 15a is connected to the power supply pad 14, and the other end of the flexible substrate 15 is the first resin. The substrate 11 and the second resin substrate 12 are exposed to the outside.

In the resin rear window 10 shown in FIGS. 1 (a), 1 (b) and 1 (c), the first resin base 11 and the second resin base 12 have an intermediate film 16 provided between them. It is crimped through. The hot wire 13 and the power supply pad 14 are disposed between the intermediate film 16 and the second resin base 12.

In the resin rear window of the present invention, the flexible substrate is not particularly limited as long as it has appropriate flexibility, and examples thereof include a film substrate, a plastic substrate, and a metal substrate. Examples of the material for the flexible substrate include polyimide, glass epoxy, glass polyimide, aluminum, iron, and polyethylene. Among these, the flexible substrate is preferably made of polyimide, and more preferably a polyimide film substrate.

In the resin rear window of the present invention, the thickness of the flexible substrate is not particularly limited, but is preferably 10 to 300 μm, and more preferably 20 to 200 μm. When the thickness of the flexible substrate is less than 10 μm, the substrate is easily bent and more easily bent, so that the connectivity with the power supply pad and the wiring tends to be lowered. On the other hand, if the thickness of the flexible substrate exceeds 300 μm, the flexibility tends to decrease.

In the flexible substrate constituting the resin rear window of the present invention, the shape, size, and number of terminals for connecting to the power supply pad are not particularly limited, and are appropriately determined according to the shape, size, and number of power supply pads. Is set.

In the resin rear window of the present invention, a Ni / Au plating layer is preferably provided on the surface of the terminal of the flexible substrate. By providing the Ni / Au plating layer on the surface of the terminal of the flexible substrate, electrical connection with the power feeding pad can be reliably performed.

In the resin rear window of the present invention, the material of the terminal of the flexible substrate is not particularly limited, but copper, nickel and the like are preferable. These materials have good electrical conductivity and are suitable as conductors.

In the resin rear window of the present invention, the thickness of the terminal of the flexible substrate is not particularly limited, but is preferably 30 to 500 μm, and more preferably 50 to 300 μm. If the thickness of the terminal is less than 30 μm, the connectivity with the power supply pad and the wiring tends to decrease, and if the thickness of the terminal exceeds 500 μm, the compressive stress due to bending of the flexible substrate increases, so that the The substrate is easily destroyed.

In the resin rear window of the present invention, the flexible substrate usually includes a conductor layer connected to the terminal. The conductor layer may be formed on one side of the flexible substrate, or may be formed on both sides. A preferable material and thickness of the conductor layer are the same as those of the terminal.

In the resin rear window of the present invention, the terminal and the conductor layer of the flexible substrate are formed by, for example, plating the surface of the insulating film, which is a substrate material, or the metal foil of the insulating film to which the metal foil is attached. The film can be formed by performing an etching process. The terminal is preferably formed as a part of the conductor layer.

In the resin rear window of the present invention, examples of the heat ray material include conductive metals or alloys such as silver, copper, tungsten, nickel, molybdenum, tantalum, nickel-chromium alloy, and iron-chromium-aluminum alloy. It is done.

In the resin rear window of the present invention, the shape of the heat ray is not particularly limited, and can take various shapes. The most basic shape includes a pattern in which a plurality of straight lines parallel to each other are formed in a horizontal direction at a predetermined interval. The shape of the heat ray may be a pattern in which a plurality of parallel wave-shaped curves are repeated at a predetermined interval, or a combination of a plurality of straight lines parallel to each other is repeated at a predetermined interval. Examples of the wave-shaped curve include a sine curve (sine curve), a shape in which an upward convex semicircle and a downward convex semicircle are repeated in the horizontal direction. Further, examples of the combination of straight lines include a shape in which a 45 ° straight line and a −45 ° straight line are repeated with respect to the horizontal direction. In the case of a combination of straight lines, the bent portion may be configured by a curve.

In the resin rear window of the present invention, the thickness of the heat ray is preferably 5 to 50 μm. The width of the heat ray is preferably 0.2 to 0.8 mm. If the width of the hot wire is less than 0.2 mm, the hot wire is too thin, and there is a risk of disconnection due to repeated heat generation. On the other hand, when the width of the hot wire exceeds 0.8 mm, it becomes difficult to increase the resistance value per unit length and it becomes difficult to generate heat, and the construction is conspicuous and is not suitable from the viewpoint of design.

In the resin rear window of the present invention, as a material for the power supply pad, for example, conductive metal or alloy such as silver, copper, tungsten, nickel, molybdenum, tantalum, nickel-chromium alloy, iron-chromium-aluminum alloy, etc. Is mentioned. The material of the power feeding pad is preferably the same material as the heat ray. This is because when a heat ray is formed using a method such as screen printing or ink jet printing, a power supply pad can be formed simultaneously.

In the resin rear window of the present invention, the shape of the power supply pad is not particularly limited, and may be any shape such as a rectangle or a circle in plan view. Further, the size and number of power supply pads are not particularly limited, and are appropriately set according to the shape, size, and number of terminals of the flexible substrate.

In the resin rear window of the present invention, it is preferable that the power supply pad is disposed on the peripheral edge portion of the resin rear window serving as an invisible portion. When the power feeding pad is disposed in the invisible portion, the visibility during driving is excellent.

In the resin rear window of the present invention, a Ni / Au plating layer is preferably provided on the surface of the power supply pad. By providing the Ni / Au plating layer on the surface of the power supply pad, electrical connection with the terminal of the flexible substrate can be reliably performed.

In the resin rear window of the present invention, it is preferable that bus bars connected to a plurality of heat wires are provided at both ends of the heat wires. Heat generation can be prevented by making the width of the bus bar wider than the width of the heat wire. In the resin rear window of the present invention, the bus bar is considered to be a part of the heat ray.

In the resin rear window of the present invention, when the bus bar is provided at both ends of the heat wire, the power supply pad is provided at the end of the bus bar. Moreover, it is preferable that a bus bar is arrange | positioned with the pad for electric power feeding at the peripheral part of the resin rear window used as an invisible part.

In the resin rear window of the present invention, when the bus bar is provided at both ends of the heat wire, the material of the bus bar is not particularly limited, but is preferably the same material as the heat wire. This is because the bus bar can be formed at the same time when the heat ray and the power supply pad are formed using a method such as screen printing or inkjet printing.

In the resin rear window of the present invention, the heat ray, the power supply pad, and the bus bar are formed by, for example, printing a conductive paste such as a silver paste on the intermediate film or the resin substrate in a pattern and then baking it. Can do.

In the resin rear window of the present invention, each of the first resin base and the second resin base is a base made of a transparent resin material. Examples of the resin material include polycarbonate (PC), polymethyl methacrylate (PMMA), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyimide (PI), polystyrene (PS), and the like. . Among these, the resin substrate is preferably made of polycarbonate or polymethyl methacrylate. Since these resins have high translucency, do not have birefringence, and have sufficient strength, they can be suitably used as a resin substrate.

In the resin rear window of the present invention, the shapes of the first resin base and the second resin base are not particularly limited, and are appropriately set according to the shape of the rear window. Usually, since the rear window is curved left and right and / or up and down, the first resin base and the second resin base are preferably curved in a curved shape.

In the resin rear window of the present invention, the first resin base and the second resin base need not be colorless, and may be colored.

In the resin rear window of the present invention, the surface roughness Rz _JIS of the first resin base and the second resin base is preferably 10 nm or more, and preferably 50 nm or less.
When the surface roughness Rz _JIS of the resin substrate is less than 10 nm, the surface area of the resin substrate is reduced, so that the adhesion between the resin substrate and the intermediate film and the adhesion with the hard coat layer described later are sufficiently obtained. It becomes difficult. On the other hand, when the surface roughness Rz _JIS of the resin substrate exceeds 50 nm, the transparency of the resin substrate tends to be lowered.
The surface roughness Rz _JIS of the first resin substrate and the second resin substrate is based on JIS B 0601: 2001 after measuring the surface contour curve using a laser microscope (VK-X200 violet specification manufactured by Keyence Corporation). Thus, the scanning distance can be measured as 30 μm.

In the resin rear window of the present invention, the thickness of the first resin substrate is preferably 1 to 5 mm. The thickness of the second resin substrate is preferably 1 to 5 mm. The thickness of the second resin substrate may be the same as or different from the thickness of the first resin substrate.
When the thicknesses of the first resin base and the second resin base are in the above ranges, the mechanical strength necessary for the rear window can be ensured, and further, distortion and the like are hardly generated in the entire rear window.

In the resin rear window of the present invention, it is preferable that the thicknesses of the first resin base and the second resin base are both constant.

In the resin rear window of the present invention, the area of the main surface of the first resin base is larger than the area of the main surface of the second resin base, and the peripheral part of the resin rear window is larger than the central part of the resin rear window. Preferably there is a thin area. In this case, it is preferable that the thicknesses of the first resin base and the second resin base are both constant. By making the area of the main surface of the first resin base larger than the area of the main surface of the second resin base, it is possible to provide an area thinner than the central part other than the peripheral part in the peripheral part of the resin rear window. .

In the resin rear window of the present invention, when a region thinner than the central portion is present in the peripheral portion, the thin region is preferably present in the invisible portion. Moreover, it is preferable that the 1st resin base | substrate with a relatively large area of a main surface is arrange | positioned at the vehicle inside, and the 2nd resin base | substrate with a relatively small area of a main surface is arrange | positioned at the vehicle inside.
The rear window can be reduced in weight by making the peripheral part that does not affect the visibility during driving thinner than the central part. Further, when the thickness of the central portion other than the peripheral portion is constant, a uniform anti-fogging effect can be obtained and the visibility during driving is excellent. Furthermore, unlike the case where the thickness is continuously reduced from the central portion toward the peripheral portion, if the thickness of the central portion is constant, the entire rear window can be prevented from becoming a lens shape. The problem of temperature unevenness due to penetration is less likely to occur.

In the resin rear window of the present invention, when a region thinner than the central portion is present in the peripheral portion, a region thinner than the central portion may exist over the entire peripheral portion, or the central portion may be part of the peripheral portion. There may be thinner regions. When a region thinner than the central portion is present in a part of the peripheral portion, the peripheral portion having the same thickness as the central portion functions as a reinforcing material (rib) for preventing deformation or the like of the rear window.

FIG. 2 is a plan view schematically showing another example of the resin rear window of the present invention.
In the resin rear window 20 shown in FIG. 2, the area of the main surface of the first resin base 21 is larger than the area of the main surface of the second resin base 22, and the entire peripheral edge of the resin rear window 20 is formed from the center. There is also a thin area.

FIG. 3 is a plan view schematically showing still another example of the resin rear window of the present invention.
In the resin rear window 30 shown in FIG. 3, the area of the main surface of the first resin base 31 is larger than the area of the main surface of the second resin base 32, and the central portion is part of the peripheral edge of the resin rear window 30. There is a thinner area.

In the resin rear window of the present invention, a primer layer is provided on at least one of the main surfaces of the first resin substrate and the second resin substrate opposite to the heat ray, and the hard layer is formed on the primer layer. A coat layer is preferably provided. The primer layer and the hard coat layer are preferably provided at least on the main surface of the resin substrate to be disposed outside the vehicle, and both main surfaces of the first resin substrate and the second resin substrate on the opposite side to the heat rays. It is more preferable to be provided on the top.

In the resin rear window of the present invention, a ceramic layer may be further provided on the hard coat layer. In this case, it is preferable that the ceramic layer is provided at least on the hard coat layer to be disposed outside the vehicle. By forming the ceramic layer on the hard coat layer, the surface hardness can be further increased and the durability can be improved.

FIG. 4 is an enlarged cross-sectional view schematically showing an example of the resin rear window of the present invention when a primer layer and a hard coat layer are provided.
In FIG. 4, as in FIG. 1C, the heat ray 13 and the intermediate film 16 are both disposed between the first resin base 11 and the second resin base 12. A primer layer 17a is provided on the main surface of the first resin substrate 11 opposite to the heat ray 13, and a hard coat layer 18a is provided on the primer layer 17a. In addition, a primer layer 17b is provided on the main surface of the second resin substrate 12 opposite to the heat ray 13, and a hard coat layer 18b is provided on the primer layer 17b. Further, a ceramic layer 19a is provided on the hard coat layer 18a on the first resin substrate 11 side. A ceramic layer may be provided on the hard coat layer 18b on the second resin substrate 12 side.

In the resin rear window of the present invention, the primer layer is a layer provided for bonding the resin substrate and the hard coat layer, and is made of a resin material.
The resin material constituting the primer layer preferably has good adhesion to the resin substrate and the hard coat layer, for example, acrylic resin, urethane resin, epoxy resin, polyester resin, polyvinyl alcohol resin, melamine resin, silicone resin, etc. Is mentioned. These can be used alone or in combination of two or more. Since these materials are excellent in adhesiveness to the resin substrate and the hard coat layer, the resin substrate and the hard coat layer can be firmly bonded via the primer layer. Especially, the material which forms a primer layer has an acrylic resin, a urethane resin, or an epoxy resin, and an acrylic resin is more preferable. The acrylic resin is a polymer of acrylic ester or methacrylic ester.

In the resin rear window of the present invention, when the primer layer is made of an acrylic resin, the acrylic resin preferably contains at least an acrylate compound having at least two ethylenically unsaturated bonds in one molecule. Of these, polyfunctional (meth) acrylates having two or more (meth) acryloyl groups in one molecule are preferable. Moreover, the said acrylic resin may use the monofunctional (meth) acrylate which has one (meth) acryloyl group in 1 molecule in combination with the said polyfunctional (meth) acrylate. By using a monofunctional (meth) acrylate in combination, the film forming property and adhesion of the hard coat layer are improved.

In the resin rear window of the present invention, the thickness of the primer layer is not particularly limited, but 1 to 10 μm is preferable and 3 to 8 μm is more preferable from the viewpoint of adhesiveness to the resin substrate and the hard coat layer.

In the resin rear window of the present invention, the hard coat layer is a layer provided to prevent the surface from being scratched, and is made of a resin material.
Examples of the resin material constituting the hard coat layer include silicone resin, silica hybrid composite, acrylic resin, melamine resin, and the like. These can be used alone or in combination of two or more. By forming a hard coat layer using these materials, the surface hardness can be increased, so that a rear window in which scratches or the like hardly occur on the surface can be obtained. Among them, the material for forming the hard coat layer is preferably a silicone resin.

In the resin rear window of the present invention, the thickness of the hard coat layer is not particularly limited, but is preferably 1 to 10 μm and more preferably 2 to 5 μm from the viewpoint of obtaining high surface hardness.

In the resin rear window of the present invention, the ceramic layer is made of an inorganic material such as an oxide ceramic, a carbide ceramic, or a nitride ceramic.
The inorganic material constituting the ceramic layer is preferably a transparent material, for example, SiOxCy (0.5 ≦ x ≦ 1.7, 0.2 ≦ y ≦ 2.0), silica (SiO ₂ ), Examples include alumina (Al ₂ O ₃ ), tin-doped indium oxide (ITO), indium oxide (In ₂ O ₃ ), tin oxide (SnO ₂ ), zinc oxide (ZnO), and titanium oxide (TiO ₂ ).

Among them, the ceramic layer, SiOxCy (0.5 ≦ x ≦ 1.7,0.2 ≦ y ≦ 2.0) or preferably consists of SiO _2.
The ceramic layer made of SiOxCy can be formed by a physical vapor deposition (PVD) method using SiO ₂ and SiC as targets, a PVD method in an oxygen atmosphere using SiC as a target, a plasma CVD method, or the like. Further, the ceramic layer of SiO ₂ may be formed of SiO ₂ target and the PVD method, a plasma CVD method or the like.

In the resin rear window of the present invention, when the first resin base and the second resin base are made of polycarbonate, the ceramic layer is preferably made of SiO ₂ , and the first resin base and the second resin base are made of polymethyl methacrylate. In this case, the ceramic layer is preferably made of SiOxCy.

In the resin rear window of the present invention, the ceramic layer is preferably amorphous. When the ceramic layer is amorphous, the ceramic layer can be made transparent.

In the resin rear window of the present invention, the thickness of the ceramic layer is not particularly limited, but is preferably 5 to 300 μm, more preferably 10 to 100 μm, from the viewpoint of obtaining high surface hardness.

The thickness of the ceramic layer can be measured using, for example, a laser microscope. The thickness of the primer layer and the hard coat layer can be measured in the same manner.
For example, the thickness of the ceramic layer is such that the primer layer, the hard coat layer and the ceramic layer are formed on the surface of the resin substrate, and the primer layer and the hard coat layer are formed on the surface of the resin substrate. Prepare a sample with a non-exposed part, and scan with a laser microscope so as to straddle the step difference between the part where the primer layer, hard coat layer and ceramic layer are formed on the surface of the resin substrate, and the part where it is not formed. The height of the step can be measured as the thickness of the ceramic layer.

In the resin rear window of the present invention, each of the primer layer, the hard coat layer, and the ceramic layer does not need to have a single layer structure, and may have a multilayer structure of two or more layers.

In the resin rear window of the present invention, as long as one end of the flexible substrate is sandwiched between the first resin base and the second resin base, the terminal of the flexible substrate is connected to the power supply pad. Part of the pads, terminals of the flexible substrate, and the like may be exposed to the outside from the first resin base and the second resin base.

In the resin rear window of the present invention, the heat ray can be used not only for anti-fogging but also for applications such as snow melting. Moreover, a heat ray may be used as an antenna wire.

[Method of manufacturing resin rear window]
The resin rear window of the present invention can be manufactured by sandwiching a heat ray, a power feeding pad, and a flexible substrate between the first resin base and the second resin base and thermocompression bonding. At this time, one end of the flexible substrate is sandwiched between the first resin substrate and the second resin substrate so that the terminals of the flexible substrate are connected to the power supply pads.

When manufacturing a resin rear window curved in a curved shape, a heat ray, a power supply pad, and a flexible substrate are sandwiched between the first resin base and the second resin base curved in a predetermined shape, and thermocompression bonded. It is preferable.

Hereinafter, as an example of a method for manufacturing a resin rear window of the present invention, an intermediate film on which a heat ray and a power supply pad are formed and a flexible substrate are sandwiched between a first resin substrate and a second resin substrate, followed by thermocompression bonding. Will be described.

(Preparation of first resin substrate and second resin substrate)
As the first resin substrate and the second resin substrate, the resin substrate described in [Resin Rear Window] can be used, and two resin substrates having a predetermined shape are prepared.

Further, it is preferable to perform a cleaning treatment in order to remove impurities on the surface of the resin substrate.
The cleaning process is not particularly limited, and a conventionally known cleaning process can be used. For example, a method of performing ultrasonic cleaning in water or an alcohol solvent can be used. Further, the surface of the resin substrate may be plasma-cleaned by installing a resin substrate in the sputtering apparatus and generating plasma.

After the washing treatment, the surface of the resin substrate may be roughened to adjust the surface roughness of the resin substrate as necessary. For example, you may perform roughening processes, such as a sandblast process and an etching process. These may be used alone or in combination of two or more.
You may perform a washing process after a roughening process.
Since the preferable surface roughness of the resin substrate surface has already been described in [Resin rear window], the description thereof is omitted here.

(Formation of heat wires and power supply pads)
The method of forming the heat ray and the power supply pad on the intermediate film is not particularly limited. However, the screen printing method, the ink jet printing method, the plating method, the method of etching the metal foil attached to the intermediate film, and the mask are used. The PVD method etc. which were made. Among these, screen printing, ink jet printing, or plating is preferable. On the intermediate film, bus bars may be formed at both ends of the hot wire.
Since the intermediate film, the heat ray, the power supply pad, and the like have already been described in [Resin rear window], description thereof is omitted here.

(Heat bonding)
The intermediate film and the flexible substrate on which the heat wires and the power supply pads are formed are sandwiched between the first resin base and the second resin base, and thermocompression bonded. At this time, one end of the flexible substrate is sandwiched between the first resin substrate and the second resin substrate so that the terminals of the flexible substrate are connected to the power supply pads.
Since the flexible substrate has already been described in [Resin rear window], the description thereof is omitted here.
Through the above steps, the resin rear window of the present invention can be manufactured.

(Formation of primer layer)
When the primer layer is formed on the main surface of the resin substrate, for example, a solution containing the resin material constituting the primer layer described in [Resin rear window] is applied on the main surface of the resin substrate and then dried. It can be cured. Or you may affix the film used as a primer layer on the main surface of a resin base | substrate.
Examples of the method for applying the solution containing the resin material include a spray coating method, a dip coating method, and a flow coating method.

(Formation of hard coat layer)
In the case of forming a hard coat layer on the primer layer, for example, a solution containing the resin material constituting the hard coat layer described in [Resin rear window] is applied on the primer layer, and then dried and cured. That's fine. Or you may affix the film used as a hard-coat layer on a primer layer.
Examples of the method for applying the solution containing the resin material include a spray coating method, a dip coating method, and a flow coating method.

The method for curing the primer layer and the hard coat layer is not particularly limited, and each method such as thermal curing, ultraviolet curing, electron beam curing, and room temperature curing can be used, and may be appropriately selected depending on the material. Further, the primer layer and the hard coat layer may be formed after the primer layer is cured, or the primer layer and the hard coat layer may be cured simultaneously.

(Ceramic layer formation)
When a ceramic layer is formed on the hard coat layer, the ceramic layer can be formed by a PVD method or a plasma CVD method.
When the ceramic layer is formed by the PVD method or the plasma CVD method, the temperature of the resin substrate made of the resin material, the primer layer, etc. does not become high, and the ceramic layer can be formed at a temperature lower than the heat resistant temperature of the resin material. It is suitable as a method for forming a ceramic layer on a resin material.

In the case of the PVD method, it is preferable to form the ceramic layer at 5 to 200 ° C. This temperature is a set temperature in the chamber, and is preferably room temperature (25 ° C. ± 15 ° C.).

The PVD method is preferably performed by sputtering, vacuum deposition, ion plating, or ion beam deposition.
Among these, it is more preferable to carry out by sputtering. Examples of the sputtering method include magnetron sputtering, ion beam sputtering, bipolar sputtering, reactive sputtering, ECR sputtering, and the like.
In particular, RF (alternating current, high frequency) sputtering is preferable, and RF magnetron sputtering is more preferable. When RF sputtering is used, sputtering is also possible for a ceramic target that is an insulator, and the film formation rate can be increased by using magnetron sputtering.

When performing RF magnetron sputtering, a target to be a material of the ceramic layer is placed in a sputtering apparatus, a resin substrate is placed in the chamber, the inside of the chamber is an Ar atmosphere, and the pressure in the chamber is, for example, 0.2 to The pressure is reduced to 1.2 Pa.
Then, sputtering is performed for a predetermined time by applying a high frequency voltage, and a ceramic layer having a predetermined thickness is formed on the hard coat layer.

When a ceramic layer made of SiOxCy (0.5 ≦ x ≦ 1.7, 0.2 ≦ y ≦ 2.0) is formed by the PVD method, both SiO ₂ and SiC are used as targets and electric power is supplied to both. The composition of SiOxCy can be controlled by adjusting the size of.
When a ceramic layer made of SiOxCy (0.5 ≦ x ≦ 1.7, 0.2 ≦ y ≦ 2.0) is formed by the PVD method, SiC is used as a target, the oxygen concentration in the atmosphere and the target The composition of SiOxCy can be controlled by adjusting the magnitude of the electric power supplied to the substrate.
On the other hand, when a ceramic layer made of SiOxCy (0.5 ≦ x ≦ 1.7, 0.2 ≦ y ≦ 2.0) is formed by the plasma CVD method, the kind of organic silicone used as a raw material and the magnitude of electric power are large. The composition of SiOxCy can be controlled by adjusting the flow rate of the source gas and the oxygen gas.

As described in [Resin Rear Window], as a method of arranging the heat ray and the power supply pad between the first resin base and the second resin base, the heat ray and the power supply pad are formed on the intermediate film. In addition to the method, a method of forming a heat ray and a power supply pad on the inner surface of the resin base, a method of inserting a film on which the heat ray and the power supply pad are formed between the intermediate film and the resin base, and the like can be mentioned. The method of forming the heat ray and the power feeding pad on the resin substrate or the film is the same as the method of forming the heat wire and the power supply pad on the intermediate film.

[Resin window]
The resin window of the present invention includes a resin base, a conductor disposed on or inside the resin base, a power supply pad connected to the conductor, and a terminal for connecting to the power supply pad. A flexible substrate, and one end of the flexible substrate is fixed to the resin base so that the terminal is connected to the power supply pad, and the other end of the flexible substrate is external to the resin base. It is exposed.

In the resin window of the present invention, the number of resin bases, the type of conductor, the position where the conductor and the power supply pad are arranged, the method of fixing the flexible substrate to the resin substrate, and the use of the window are not limited. It differs from the resin rear window of the invention.

FIG. 5 is a plan view schematically showing an example of the resin window of the present invention.
A resin window 40 shown in FIG. 5 includes a resin base 41, a conductor 43 disposed on the surface of the resin base 41, a power supply pad 44 connected to the conductor 43, and a power supply pad 44. And a flexible substrate 45 having terminals (not shown). The conductor 43 and the power supply pad 44 are both disposed on the surface of the resin base 41.

One end of the flexible substrate 45 is fixed to the resin base 41 so that the terminal is connected to the power supply pad 44, and the other end of the flexible substrate 45 is exposed to the outside from the resin base 41. In the resin window 40 shown in FIG. 5, the flexible substrate 45 is further fixed to the resin base 41 with an adhesive tape 46.

In the resin window of the present invention, the number of resin bases is not particularly limited, and may be one, two, or three or more. The total thickness of the resin substrate is preferably 1 to 10 mm.
The material, shape, and the like of the resin base are the same as those of the first resin base and the second resin base described in [Resin rear window], and thus description thereof is omitted here.

In the resin window of the present invention, the position where the conductor and the power supply pad are arranged is not particularly limited. For example, when the number of the resin base is one, it is preferable that the conductor and the power supply pad are disposed on the surface of the resin base. When there are two or more resin substrates, the conductor and the power feeding pad may be disposed on the surface of the resin substrate, or may be disposed inside the resin substrate.
In the resin window of the present invention, the conductor disposed on the resin substrate is not limited to the heat ray.
The material, shape, and the like of the heat wire and the power supply pad have been described in [Resin rear window], and thus description thereof is omitted here.
Similar to the resin rear window of the present invention, a Ni / Au plating layer is preferably provided on the surface of the power feeding pad. Moreover, it is preferable that the bus bar connected with a some conductor is provided in the both ends of conductors, such as a heat ray.

In the resin window of the present invention, the method of fixing the flexible substrate to the resin substrate is not particularly limited, and other than the method of sandwiching the flexible substrate between two resin substrates, for example, a conductive paste such as silver paste A method of fixing the flexible substrate to the resin substrate using an adhesive tape and the like, while fixing the terminal of the flexible substrate and the power feeding pad using the adhesive.
Since the material and thickness of the flexible substrate and the material and thickness of the terminal have been described in [Resin rear window], the description thereof is omitted here.
Similar to the resin rear window of the present invention, a Ni / Au plating layer is preferably provided on the surface of the terminal of the flexible substrate.

In the resin window of the present invention, it is preferable that a primer layer is provided on the resin substrate, and a hard coat layer is provided on the primer layer. A ceramic layer may be further provided on the hard coat layer.
When the conductor and the power feeding pad are arranged on the surface of the resin base, a primer layer is provided on the resin base including the conductor and the power feeding pad.
Since the primer layer, the hard coat layer, and the ceramic layer have been described in [Resin rear window], description thereof is omitted here.

The resin window of the present invention is preferably used as glass for automobiles, and specifically, it is preferably used for a rear window, a front window, or a side window. Among these, it is preferable to be used for a rear window.

10, 20, 30 Resin rear window 11, 21, 31 First resin base 12, 22, 32 Second resin base 13 Heating wire 14 Power supply pad 15 Flexible substrate 15a Terminal 16 Intermediate film 17a, 17b Primer layer 18a, 18b Hard Coat layer 19a Ceramic layer 40 Resin window 41 Resin substrate 43 Conductor 44 Power supply pad 45 Flexible substrate 46 Adhesive tape

Claims (7)

A first resin substrate;
A second resin base disposed to face the first resin base;
A heat wire disposed between the first resin substrate and the second resin substrate; and a power supply pad connected to the heat wire;
A flexible substrate comprising a terminal for connecting to the power supply pad,
One end of the flexible substrate is sandwiched between the first resin base and the second resin base so that the terminal is connected to the power supply pad,
The resin rear window is characterized in that the other end of the flexible substrate is exposed to the outside from the first resin base and the second resin base. 2. The resin rear window according to claim 1, wherein each of the first resin base and the second resin base is made of polycarbonate or polymethyl methacrylate. The resin rear window according to claim 1, wherein the flexible substrate is made of polyimide. The resin-made rear window according to any one of claims 1 to 3, wherein a Ni / Au plating layer is provided on a surface of the power supply pad and a surface of a terminal of the flexible substrate. The area of the main surface of the first resin substrate is larger than the area of the main surface of the second resin substrate,
The resin rear window according to any one of claims 1 to 4, wherein an area thinner than a central portion of the resin rear window is present at a peripheral edge portion of the resin rear window. A primer layer is provided on at least one of the main surfaces of the first resin substrate and the second resin substrate opposite to the heat ray, and a hard coat layer is provided on the primer layer. The resin rear window according to claim 1. A resin substrate;
A conductor disposed on or inside the resin substrate, and a power supply pad connected to the conductor;
A flexible substrate comprising a terminal for connecting to the power supply pad,
One end of the flexible substrate is fixed to the resin base so that the terminal is connected to the power supply pad,
The other end of the flexible substrate is exposed to the outside from the resin substrate.

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