Packaged film assembly for lamination between substrates

Abstract

A packaged film assembly includes a packaging material and an insert film. The insert film is packaged in and attached to at least a portion of the packaging material. The packaging material is not laminated to another surface.

1 . A packaged film assembly, comprising:
 (a) a packaging material; and   (b) an insert film packaged in and attached to at least a portion of the packaging material, wherein the packaging material is not laminated to another surface.   
     
     
         2 . The assembly of  claim 1  wherein the packaging material comprises polyvinyl butyral (“PVB”) or ethylene-vinyl acetetate (“EVA”). 
     
     
         3 . The assembly of  claim 1  wherein the insert film is a switchable film configured to switch between a dark state and a light state. 
     
     
         4 . The assembly of  claim 3  wherein the switchable film transitions from the light state to the dark state upon exposure to sunlight and from the dark state to the light state when a voltage is applied across the switchable film absent exposure of the switchable film to sunlight. 
     
     
         5 . The assembly of  claim 3  wherein the switchable film comprises polyethylene terephthalate (“PET”). 
     
     
         6 . The assembly of  claim 1  wherein the packaging material comprises a first and a second interlayer, wherein the first interlayer comprises a first film laminable to a first substrate and in direct contact with a first side of the insert film and wherein the second interlayer comprises a second film laminable to a second substrate and in direct contact with a second side of the insert film that is opposite to the first side. 
     
     
         7 . The assembly of  claim 6  wherein the first and second films overlap and are secured to each other at one or more overlapping portions around the insert film. 
     
     
         8 . The assembly of  claim 7  wherein the one or more overlapping portions comprises a single overlapping portion that circumscribes at least part of the insert film. 
     
     
         9 . The assembly of  claim 8  wherein the single overlapping portion circumscribes the entirety of the insert film. 
     
     
         10 . The assembly of  claim 9  further comprising a bonding material in the overlapping portion that bonds the first and second films to each other. 
     
     
         11 . The assembly of  claim 7  wherein the one or more overlapping portions comprises discrete regions located around the insert film. 
     
     
         12 . The assembly of  claim 11  wherein the discrete regions delimit a pouch that contains the insert film. 
     
     
         13 . The assembly of  claim 6  wherein the first film is bonded directly to the first side of the insert film and the second film is bonded directly to the second side of the insert film. 
     
     
         14 . The assembly of  claim 13  wherein the first and second films are bonded to the insert film along a periphery of the insert film to form an edge seal. 
     
     
         15 . The assembly of  claim 6  wherein the insert film comprises:
 (a) a pair of PET coverlays located between the first and second films, wherein one of the PET coverlays is secured to the first film and the other of the PET coverlays is secured to the second film; 
 (b) a pair of electrically conductive electrodes located between the PET coverlays, wherein one of the electrodes is secured to one of the PET coverlays and the other of the electrodes is secured to the other of the PET coverlays, and wherein each of the electrodes comprises an overhanging portion that extends past an edge of the other of the electrodes; 
 (c) a pair of bus bars, wherein one of the bus bars is electrically coupled to the overhanging portion of one of the electrodes and the other of the bus bars is electrically coupled to the overhanging portion of the other of the electrodes; 
 (d) a switching material located between the electrodes; and 
 (e) an epoxy between and bonding the PET coverlays to each other. 
 
     
     
         16 . The assembly of  claim 1  wherein the packaging material comprises a frame that extends around at least a portion of the insert film. 
     
     
         17 . The assembly of  claim 16  wherein the packaging material circumscribes the entirety of the insert film. 
     
     
         18 . The assembly of  claim 16  wherein the frame comprises de-airing channels extending from an interior edge to an exterior edge of the frame. 
     
     
         19 . The assembly of  claim 16  wherein the frame comprises tabs extending towards the insert film, and wherein the insert film is attached to the tabs. 
     
     
         20 . The assembly of  claim 16  wherein the packaging material further comprises a first film laminable to a first substrate and in direct contact with a first side of the frame and a second film laminable to a second substrate and in direct contact with a second side of the frame that is opposite to the first side. 
     
     
         21 . The assembly of  claim 20  further comprising:
 (a) a pair of bus bars located between the first and second films, wherein one of the bus bars is attached to the first film and the other of the bus bars is attached to the second film; 
 (b) a pair of PET substrates located between the first and second films, wherein one of the PET substrates is secured to the first film and the other of the PET substrates is secured to the second film, and wherein each of the PET substrates comprises an overhanging portion that extends past an edge of the other of the PET substrates; 
 (c) a pair of electrical coatings located between the PET substrates, wherein one of the electrical coatings is on one of the PET substrates and the other of the electrical coatings is on the other of the PET substrates; and 
 (d) a switching material located between the electrical coatings. 
 
     
     
         22 . A method for manufacturing a packaged film assembly, the method comprising:
 (a) forming a packaging material;   (b) forming an insert film; and   (c) packaging the insert film in the packaging material, wherein the packaging material is not laminated to another surface and wherein packaging the insert film comprises attaching the insert film to at least a portion of the packaging material.   
     
     
         23 . The method of  claim 22  wherein forming the packaging material comprises:
 (a) forming a frame; and 
 (b) forming first and second sheets manufactured from a laminable material, and wherein the method further comprises: 
 (c) laying the first sheet on a flat surface; 
 (d) aligning the frame on the first sheet; 
 (e) aligning the insert film within the frame; 
 (f) aligning the second sheet on the frame and the insert film; and 
 (g) attaching each of the first and second sheets to opposing sides of the frame.