CN107097483A - 电加热功能的汽车玻璃及加热方法 - Google Patents
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Abstract
一种电加热功能的汽车玻璃及加热方法。丝印银浆汽车后挡风玻璃为较传统的工艺,银浆最细宽度约1mm左右,整体印刷银浆材料成本高,且加热线较粗不仅影响美观而且对驾驶者观察车后环境有一定的阻隔。一种电加热功能的汽车玻璃,其组成包括:粘结层(3)、金属网格(4)和连接端子(6),连接端子直接焊接在金属网格的母线电极上,母线电极、金属网格和连接端子构组成金属网格导电层,粘结层位于外玻璃基板(1)和金属网格导电层之间,金属网格导电层和内玻璃基板(2)之间设置有夹层聚合物(7),金属网格和母线电极组成母版图形,金属网格的导电层采用磁控溅射的方式溅镀一层薄铜。本发明应用于汽车玻璃领域。
Description
技术领域:
本发明涉及一种电加热功能的汽车玻璃及加热方法。
背景技术:
目前,市场上具有电加热功能的汽车玻璃大致有两种:丝印银浆汽车后挡风玻璃,电钨丝汽车前档风玻璃。
丝印银浆汽车后挡风玻璃为较传统的工艺,银浆最细宽度约1mm左右,整体印刷银浆材料成本高,且加热线较粗不仅影响美观而且对驾驶者观察车后环境有一定的阻隔。而电钨丝汽车前挡风玻璃钨丝为约35μm左右的柱形,材料本身生产成本高,且要将其按一定的顺序排布在玻璃上合片制作夹层玻璃,工艺也很复杂,因此目前仅在一些中高端汽车上得到应用。
制备一种成本低、工艺简单的具有加热功能的汽车玻璃逐渐引起人们的重视。现有技术中,专利CN102173133 A公开了一种ITO膜与纳米银线结合的加热玻璃,先在玻璃上磁控溅射一层ITO在玻璃成型,然后再涂布一层纳米材料。这种方法制作在玻璃弯曲时ITO膜可能会断裂或者因高温膜阻值变化,且纳米银线雾度大,在汽车玻璃安全要求的前提下制作难度依然很大。专利CN204183964 U中公布了一种附着在透明薄膜基材上的金属网格,图形中有孔洞增加透过率和夹层玻璃整体的机械强度。该方法将金属网格制备在薄膜基材上再层压在玻璃之间,工艺相对较复杂,且容易造成层压时薄膜褶皱产品不良,另外网格连接母线处需承受10~15A的电流,该专利未阐释母线制作方式,若沿用传统银浆母线,成本依然很高。
发明内容:
本发明的目的是提供一种电加热功能的汽车玻璃及加热方法,具有美观、高透过率、能够除霜除雾而且成本较低的电加热功能汽车玻璃,该汽车玻璃采用磁控溅射镀膜和电镀的方式直接将导电层制作在玻璃上,工艺更直接,省去透明薄膜做基材的步骤,而且能够与玻璃相配,不存在玻璃弯曲成型时导电层断裂的问题,电极也在导电层制作的过程中一体成型,且满足加热,省去银浆母线,节约了成本,并且也符合透光和美观的要求。
上述的目的通过以下的技术方案实现:
一种电加热功能的汽车玻璃,其组成包括:粘结层、金属网格和连接端子,所述的连接端子直接焊接在所述的金属网格的母线电极上,所述的母线电极、所述的金属网格和所述的连接端子构组成金属网格导电层,所述的粘结层位于外玻璃基板和所述的金属网格导电层之间,所述的金属网格导电层和内玻璃基板之间设置有夹层聚合物,所述的金属网格和母线电极组成母版图形,所述的金属网格的导电层采用磁控溅射的方式溅镀一层薄铜,再用电镀工艺增厚至需要的厚度。
所述的电加热功能的汽车玻璃,所述的所述的粘结层为透明氧化物、氮化物或金属化合物薄膜,即TiO2、TiN、NiCr、Si3N4,其厚度为20~200nm。
所述的电加热功能的汽车玻璃,所述的金属网格导电层材料为Cu、Ag、Ti、Al、Ni或者Zn,采用磁控溅射的方式在粘结层上溅射一层薄膜,其厚度为500~2000nm,然后采用电镀的方式增厚至10~30μm。
所述的电加热功能的汽车玻璃,所述的母版图形的金属网格为长方形、正方形、菱形、六边形、圆形或者它们的组合图形中的至少一种,网格的线宽为10~100μm,网格等效孔径为800~3000μm。网格等效方阻为0.5~5Ω/□。
所述的电加热功能的汽车玻璃,所述的母版图形中所述的母线电极在所述的金属网格蚀刻过程中一起成型,其所述的母线电极厚度等于所述的金属网格厚度,且所述的母线电极采用多点并联的树形结构连接在所述的金属网格上,所述的母线电极宽度为8~20μm。
所述的电加热功能的汽车玻璃的加热方法,该方法包括如下步骤:
金属网格制备分为两个步骤:首先制备金属膜层的方式为先用磁控溅射制备一层较薄的导电薄膜,在电镀增厚至需要的厚度,然后采用化学蚀刻的方式制备出需要的金属网格图形和电极;
若采用激光蚀刻的方式需要在磁控溅射后做蚀刻再电镀增厚网格,这是因为导电膜越厚,激光蚀刻需要的能量就要越高,技术成本等要求将更大,因此先在薄铜上做图形处理再电镀增厚;
在金属膜上涂布感光胶或贴附干膜,使用母版图形UV曝光,然后显影蚀刻出金属网格和母线电极,网格再使用回流焊在母线电极的中间位置焊接连接端子,再磁控溅射一层表面保护膜系,要求透明绝缘耐高温膜系,使用氧化物或者氮化物陶瓷材料,最后再对玻璃弯刚成型。
本发明的有益效果:
1.本发明在制备金属网格图形的时候,电极与加热功能的金属网格区一起成型,省去单独制作电极这一步骤,且不需要银浆做母线,节省了制作成本。另采用多点并联的树形结构化解电极载流量大的问题,完美的解决了低成本母线问题,且金属材料可焊性良好,可以直接连接导线至电源。
本发明通过制备金属网格及一体成型的电极制备的电加热功能汽车玻璃,满足可见光透过率大于70%,在汽车电源12V的加载下,无需升压模块即可完成加热功能,且加热区线路在驾驶员观察的距离基本达到隐形效果,整体美观,且制作成本较低。有利于行成加热汽车玻璃的新产品。
本发明的粘结层、金属网格导电层和连接端子,可以在表面磁控溅射一层透明保护膜用于汽车后挡风玻璃,也可以使用PVB夹胶工艺将该膜层层压在汽车前挡风玻璃中实现加热功能。
附图说明:
附图1是本发明的结构示意图。
附图2是附图1的俯视图。
附图3是电极多点并联树形结构示意图。
具体实施方式:
实施例1:
一种电加热功能的汽车玻璃,其组成包括:粘结层3、金属网格4和连接端子6,所述的连接端子直接焊接在所述的金属网格的母线电极上,所述的母线电极、所述的金属网格和所述的连接端子构组成金属网格导电层,所述的粘结层位于外玻璃基板1和所述的金属网格导电层之间,所述的金属网格导电层和内玻璃基板2之间设置有夹层聚合物7,所述的金属网格和母线电极组成母版图形,所述金属网格的导电层采用磁控溅射的方式溅镀一层薄铜,再用电镀工艺增厚至需要的厚度。
实施例2:
根据实施例1所述的电加热功能的汽车玻璃,所述的所述的粘结层为透明氧化物、氮化物或金属化合物薄膜,即TiO2、TiN、NiCr、Si3N4,其厚度为20~200nm。
实施例3:
根据实施例1或2所述的电加热功能的汽车玻璃,所述的金属网格导电层材料为Cu、Ag、Ti、Al、Ni或者Zn,采用磁控溅射的方式在粘结层上溅射一层薄膜,其厚度为500~2000nm,然后采用电镀的方式增厚至10~30μm。
实施例4:
根据实施例1所述的电加热功能的汽车玻璃,所述的母版图形的金属网格为长方形、正方形、菱形、六边形、圆形或者它们的组合图形中的至少一种,网格的线宽为10~100μm,网格等效孔径为800~3000μm。网格等效方阻为0.5~5Ω/□。
实施例5:
根据实施例1或2或3或4所述的电加热功能的汽车玻璃,所述的母版图形中所述的母线电极在所述的金属网格蚀刻过程中一起成型,其所述的母线电极厚度等于所述的金属网格厚度,且所述的母线电极采用多点并联的树形结构连接在所述的金属网格上,所述的母线电极宽度为8~20μm。
实施例6:
金属网格制备分为两个步骤:首先制备金属膜层的方式为先用磁控溅射制备一层较薄的导电薄膜,在电镀增厚至需要的厚度。然后采用化学蚀刻的方式制备出需要的金属网格图形和电极。若采用激光蚀刻的方式需要在磁控溅射后做蚀刻再电镀增厚网格,这是因为导电膜越厚,激光蚀刻需要的能量就要越高,技术成本等要求将更大,因此先在薄铜上做图形处理再电镀增厚。
实施例7:
对完成预处理的外玻璃基板磁控溅射粘结层,所用粘结层材料为TiO2、TiN、NiCr、Si3N4等材料中的至少一种,膜厚为20~200nm;
使用TiO2材料溅射50~100nm。然后再溅射一层导电性良好的金属Cu、Ag、Ti、Al、Ni或者Zn,膜厚500~2000nm;
使用Cu靶溅射1500~2000nm,然后再电镀增厚至10~30μm,在金属膜上涂布感光胶或贴附干膜,使用母版图形UV曝光,然后显影蚀刻出金属网格和母线电极,网格再使用回流焊在母线电极的中间位置焊接连接端子,再磁控溅射一层表面保护膜系,要求透明绝缘耐高温膜系,使用氧化物或者氮化物陶瓷材料,最后再对玻璃弯刚成型。
Claims (6)
1.一种电加热功能的汽车玻璃,其组成包括:粘结层、金属网格和连接端子,其特征是:所述的连接端子直接焊接在所述的金属网格的母线电极上,所述的母线电极、所述的金属网格和所述的连接端子构组成金属网格导电层,所述的粘结层位于外玻璃基板和所述的金属网格导电层之间,所述的金属网格导电层和内玻璃基板之间设置有夹层聚合物,所述的金属网格和母线电极组成母版图形,所述的金属网格的导电层采用磁控溅射的方式溅镀一层薄铜,再用电镀工艺增厚至需要的厚度。
2.根据权利要求1所述的电加热功能的汽车玻璃,其特征是:所述的所述的粘结层为透明氧化物、氮化物或金属化合物薄膜,即TiO2、TiN、NiCr、Si3N4,其厚度为20~200nm。
3.根据权利要求1或2所述的电加热功能的汽车玻璃,其特征是:所述的金属网格导电层材料为Cu、Ag、Ti、Al、Ni或者Zn,采用磁控溅射的方式在粘结层上溅射一层薄膜,其厚度为500~2000nm,然后采用电镀的方式增厚至10~30μm。
4.根据权利要求1或2或3所述的电加热功能的汽车玻璃,其特征是:所述的母版图形的金属网格为长方形、正方形、菱形、六边形、圆形或者它们的组合图形中的至少一种,网格的线宽为10~100μm,网格等效孔径为800~3000μm。网格等效方阻为0.5~5Ω/□。
5.根据权利要求1或2或3或4所述的电加热功能的汽车玻璃,其特征是:所述的母版图形中所述的母线电极在所述的金属网格蚀刻过程中一起成型,其所述的母线电极厚度等于所述的金属网格厚度,且所述的母线电极采用多点并联的树形结构连接在所述的金属网格上,所述的母线电极宽度为8~20μm。
6.一种权利要求1—5之一所述的电加热功能的汽车玻璃的加热方法,其特征是:该方法包括如下步骤:
金属网格制备分为两个步骤:首先制备金属膜层的方式为先用磁控溅射制备一层较薄的导电薄膜,在电镀增厚至需要的厚度,然后采用化学蚀刻的方式制备出需要的金属网格图形和电极;
若采用激光蚀刻的方式需要在磁控溅射后做蚀刻再电镀增厚网格,这是因为导电膜越厚,激光蚀刻需要的能量就要越高,技术成本等要求将更大,因此先在薄铜上做图形处理再电镀增厚;
在金属膜上涂布感光胶或贴附干膜,使用母版图形UV曝光,然后显影蚀刻出金属网格和母线电极,网格再使用回流焊在母线电极的中间位置焊接连接端子,再磁控溅射一层表面保护膜系,要求透明绝缘耐高温膜系,使用氧化物或者氮化物陶瓷材料,最后再对玻璃弯刚成型。
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