CN110049865B - 具有改进的平坦度的玻璃层合物及其形成方法 - Google Patents

具有改进的平坦度的玻璃层合物及其形成方法 Download PDF

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Publication number
CN110049865B
CN110049865B CN201780053543.1A CN201780053543A CN110049865B CN 110049865 B CN110049865 B CN 110049865B CN 201780053543 A CN201780053543 A CN 201780053543A CN 110049865 B CN110049865 B CN 110049865B
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China
Prior art keywords
glass
barrier film
glass substrate
laminate
glass laminate
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Expired - Fee Related
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CN201780053543.1A
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CN110049865A (zh
Inventor
金知满
李龟洙
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Corning Inc
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Corning Inc
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Abstract

玻璃层合物包含具有第一表面和与第一表面相反的第二表面的非玻璃基材。玻璃片层合至非玻璃基材的第一表面。阻挡膜层合至非玻璃基材的第二表面，并包含与非玻璃基材相邻的第一表面和与第一表面相反的第二表面。阻挡膜的厚度可以是至多约0.5mm。阻挡膜的第二表面可限定玻璃层合物的外表面。阻挡膜可以是具有金属层和聚合物层的多层阻挡膜。在23℃和90％相对湿度下经历7天后，玻璃层合物按照欧洲标准EN 438测定的平坦度绝对值可为至多约3mm/m。

Description

具有改进的平坦度的玻璃层合物及其形成方法
技术领域
本申请要求2016年8月31日提交的韩国申请第10-2016-0112061号的优先权，其完整内容通过参考纳入本文。
本公开涉及玻璃层合物，更具体地涉及包含层合至非玻璃基材上的玻璃片且在经受温度和/或湿度变化后具有改进的平坦度的层合物。
技术背景
玻璃层合物一般包含层合至非玻璃基材上的玻璃片。这种玻璃层合物可用作建筑板，所述建筑板可用作墙板、后挡板、橱柜表面或家具表面、器具表面或其他建筑应用。玻璃层合物可能经历较大的温度和/或湿度变化(例如在形成、运输、安装和/或使用过程中)，这可能导致非玻璃基材膨胀或收缩。非玻璃基材的这种膨胀或收缩可能在玻璃层合物内部引起机械应力，导致玻璃层合物弯曲、开裂、脱层或产生其他缺陷。
发明公开
针对问题的方案
本文公开了具有改进的平坦度的玻璃层合物及其形成方法。
本文公开了一种包含非玻璃基材的玻璃层合物，所述非玻璃基材包含第一表面和与第一表面相反的第二表面。玻璃片层合至非玻璃基材的第一表面。阻挡膜层合至非玻璃基材的第二表面，所述阻挡膜包含与非玻璃基材相邻的第一表面、与该第一表面相反的第二表面以及至多约0.5mm的厚度。阻挡膜的第二表面限定玻璃层合物的外表面。
本文公开了一种包含非玻璃基材的玻璃层合物，所述非玻璃基材包含第一表面和与第一表面相反的第二表面。玻璃片层合至非玻璃基材的第一表面。多层阻挡膜层合至非玻璃基材的第二表面，所述多层阻挡膜包含金属层和聚合物层。在23℃和90％相对湿度下经历7天后，玻璃层合物按照欧洲标准EN 438测定的平坦度绝对值为至多约3mm/m。
本文公开了一种形成玻璃层合物的方法。所述方法包括将玻璃片层合至非玻璃基材的第一表面。将多层阻挡膜层合至非玻璃基材的第二表面，所述多层阻挡膜包含金属层和聚合物层。
应理解，前面的一般性描述和以下的详细描述都仅仅是示例性的，用来提供理解要求权利的主题的性质和特性的总体评述或框架。所附附图提供了对本发明的进一步理解，附图被结合在本说明书中并构成说明书的一部分。附图说明了一个或多个实施方式，并与文字描述一起用来解释各个实施方式的原理和操作。
附图简述
图1是玻璃层合物的一个示例的横截面示意图，在非玻璃基材的与玻璃片相反的表面上没有层合阻挡膜。
图2是经历低湿度后置于平坦测试表面上的图1所示玻璃层合物的横截面示意图。
图3是经历高湿度后置于平坦测试表面上的图1所示玻璃层合物的横截面示意图。
图4是玻璃层合物的一个示例的横截面示意图，在非玻璃基材的与玻璃片相反的表面上层合有阻挡膜。
发明的具体实施方式
下面详细描述附图所示的示例性实施方式。在任何可能的情况下，相同的附图标记在所有附图中用来指示相同或类似的部件。部件在图中不一定符合比例，重点在于阐释示例性实施方式的原理。
如本文所用，术语“平坦度”是指按照欧洲标准EN 438测定的玻璃层合物或其组件的平坦度，该标准通过参考完整地纳入本文。平坦度是市售高压层合(HPL)材料一般要报告的性质。玻璃层合物的平坦度可在玻璃层合物在升高的温度和/或湿度下经历预定时间之前或之后测定。例如，本文所述的各种玻璃层合物的平坦度是在玻璃层合物在23℃和90％相对湿度下经历7天之后测定的。
如本文所用，术语“平坦度变化”是指玻璃层合物经历升高的温度和/或湿度之前的平坦度与玻璃层合物经历升高的温度和/或湿度之后的平坦度之差。
如本文所用，术语“水蒸气透过率”是指材料或层的水蒸气透过率，它可按照ASTMF1249-13“利用调制红外传感器经塑料膜和片材测量水蒸气透过率的标准测试方法”(Standard Test Method for Water Vapor Transmission Rate Through Plastic Filmand Sheeting Using a Modulated Infrared Sensor)或ASTME398-13“利用动态相对湿度测量法测量片材的水蒸气透过率的标准测试方法”(Standard Test Method for WaterVapor Transmission Rate of Sheet Materials Using Dynamic Relative HumidityMeasurement)，它们各自通过参考完整地纳入本文。
在多种实施方式中，玻璃层合物包含非玻璃基材，所述非玻璃基材包含第一表面和与第一表面相反的第二表面。玻璃片层合至非玻璃基材的第一表面。阻挡膜层合至非玻璃基材的第二表面。阻挡膜包含与非玻璃基材相邻的第一表面和与第一表面相反的第二表面。在一些实施方式中，阻挡膜是包含金属层和聚合物层的多层阻挡膜。作为附加或替代形式，阻挡膜的厚度为至多约0.5mm。作为附加或替代形式，阻挡膜的第二表面限定玻璃层合物的外表面。作为附加或替代形式，在23℃和90％相对湿度下经历7天后，玻璃层合物按照欧洲标准EN 438测定的平坦度绝对值为至多约3mm/m。
在多种实施方式中，形成玻璃层合物的方法包括将玻璃片层合至非玻璃基材的第一表面，并将多层阻挡膜层合至非玻璃基材的第二表面。多层阻挡膜包含金属层和聚合物层。在一些实施方式中，非玻璃基材在层合所述玻璃片和层合所述多层阻挡膜之前形成。例如，所述方法包括在层合玻璃片之前，通过压制一堆聚合物浸渍纸来粘接聚合物浸渍纸，从而形成非玻璃基材。在一些实施方式中，压制该堆聚合物浸渍纸包括高压层合(HPL)法或低压层合(LPL)法。
令人吃惊的是，相比于在非玻璃基材内嵌埋一个或多个抗湿层的玻璃层合物，如本文所述在与玻璃片相反的非玻璃基材表面上层合有阻挡膜的玻璃层合物表现出改进的平坦度，尤其是在经历升高的温度和湿度之后。
图1是玻璃层合物100的一个示例的横截面示意图，其包含非玻璃基材102和通过粘合剂106层合至非玻璃基材的玻璃片104。非玻璃基材102包含第一表面108和与该第一表面相反的第二表面110。玻璃片104包含第一表面112和第二表面114。玻璃片104层合至非玻璃基材102的第一表面108。因此，非玻璃基材102的第一表面108通过粘合剂106粘接至玻璃片104的第二表面114。玻璃层合物100不含任何层合至非玻璃基材102的第二表面110的阻挡层。因此，非玻璃基材102的第二表面110是玻璃层合物100的外表面，而玻璃片104的第一表面112是玻璃层合物100的另一个外表面。
在图1所示的示例中，非玻璃基材102是由多张聚合物浸渍纸形成的HPL材料。玻璃一般被认为是气密性材料，而非玻璃基材102的HPL材料比玻璃片104具有显著更高的水蒸气透过率(WVTR)。因此，水分能够经由非玻璃基材102的第二表面110进出玻璃层合物100，但水分基本上不能经由玻璃片104的第一表面112进出玻璃层合物。尽管水分能够经由非玻璃基材的第二表面110进出非玻璃基材102，由于玻璃片104层合至非玻璃基材的第一表面108，水分基本上不能经由非玻璃基材的第一表面进出非玻璃基材。
图2是经历低湿度后置于平坦测试表面150上的玻璃层合物100的横截面示意图。由于经历低湿度，水分能够离开非玻璃基材102，造成非玻璃基材相对于玻璃片104收缩或缩小。这种收缩会导致玻璃层合物100朝着玻璃片104向上弯曲152，如图2所示。如本文所用，玻璃层合物向上弯曲用正(+)平坦度值标记，导致玻璃片104相对于朝着非玻璃基材102的方向被置于凹陷取向。将玻璃片104置于这种凹陷取向导致玻璃片中形成拉伸应力，这会降低玻璃片强度和/或造成玻璃片失效。
图3是经历高湿度后置于平坦测试表面150上的玻璃层合物100的横截面示意图。由于经历高湿度，水分能够进入非玻璃基材102，造成非玻璃基材相对于玻璃片104膨胀。这种膨胀会导致玻璃层合物100在远离玻璃片104向下的方向上弯曲154，如图3所示。如本文所用，玻璃层合物向下弯曲用正(-)平坦度值标记，导致玻璃片104相对于朝着非玻璃基材102的方向被置于凸起取向。将玻璃片104置于这种凸起取向导致玻璃片中形成压缩应力，这会提高玻璃片强度。
图4是玻璃层合物200的一个实施方式的横截面示意图。玻璃层合物200在一些方面类似于参考图1所述的玻璃层合物100。例如，玻璃层合物200包含非玻璃基材202和通过粘合剂206层合至非玻璃基材的玻璃片204。非玻璃基材102包含第一表面208和与该第一表面相反的第二表面210。玻璃片204包含第一表面212和第二表面214。玻璃片204层合至非玻璃基材202的第一表面208。因此，非玻璃基材202的第一表面208通过粘合剂206粘接至玻璃片204的第二表面214。
与玻璃层合物100不同，图4所示的玻璃层合物200包含通过粘合剂222层合至非玻璃基材的阻挡膜220。阻挡膜220包含第一表面224和与该第一表面相反的第二表面226。阻挡膜220层合至非玻璃基材202的第二表面210。因此，非玻璃基材202的第二表面210通过粘合剂222粘接至阻挡膜220的第一表面224。在一些实施方式中，阻挡膜220的第二表面226是玻璃层合物200的外表面，而玻璃片204的第一表面212是玻璃层合物200的另一个外表面。
在一些实施方式中，非玻璃基材202是HPL材料，阻挡膜220具有基本上比非玻璃基材低的WVTR。例如，阻挡膜220可视为气密性材料。因此，水分基本上不能经由玻璃片104或经由阻挡膜220进出玻璃层合物200。因为玻璃片204层合至非玻璃基材202的第一表面208，水分基本上不能经由非玻璃基材的第一表面进出非玻璃基材。类似地，因为阻挡膜220层合至非玻璃基材202的第二表面210，水分基本上不能经由非玻璃基材的第二表面进出非玻璃基材。
通过基本上阻止水分在非玻璃基材的第一表面208和第二表面210进出非玻璃基材202，玻璃片204和阻挡膜220协同帮助防止非玻璃基材在玻璃层合物200经历升高的温度和湿度时发生与湿度相关的膨胀和收缩，这可有助于防止玻璃层合物弯曲和/或玻璃片破裂。令人吃惊的是，相比于嵌埋在非玻璃基材中的抗湿层，如图4所示层合至与玻璃片204相反的非玻璃基材202第二表面210的阻挡膜220能更有效地防止玻璃层合物200弯曲，如下文进一步所解释。因此，即使玻璃层合物100的非玻璃基材102包含一个或多个嵌埋在非玻璃基材中的抗湿层，在非玻璃基材202的第二表面210上层合有阻挡膜220的玻璃层合物200与玻璃层合物100相比也表现出改善的平坦度。
在多种实施方式中，非玻璃基材202主要由非玻璃材料形成或者主要包含非玻璃材料。例如，非玻璃基材202包含木材、纤维板、层合材料、复合材料、聚合物材料和/或金属材料。在一些实施方式中，非玻璃基材202包含木材产品或基于木材的产品，如木屑板、颗粒板、纤维板、卡纸板、硬纸板或纸。在一些这样的实施方式中，非玻璃基材202包含LPL、HPL和/或胶合板。在一些实施方式中，非玻璃基材202包含一层或多层本文所述的聚合物浸渍纸。在一些实施方式中，非玻璃基材202选自下组，该组由以下各项组成：高压层合(HPL)板、低压层合(LPL)板、木质人造板、聚合物板及其组合。在一些实施方式中，非玻璃基材202包含玻璃、玻璃陶瓷和/或陶瓷材料作为第二组分(例如填料)。不过，在这样的实施方式中，非玻璃基材202不含玻璃片、玻璃陶瓷片或陶瓷片(例如实心或基本上实心的片材，不同于纤维垫或编织物)。
在一些实施方式中，非玻璃基材202由聚合物材料形成或者包含聚合物材料。例如，非玻璃基材包含聚对苯二甲酸乙二酯(PET)、聚萘二甲酸乙二酯(PEN)、乙烯四氟乙烯(ETFE)或热聚合物聚烯烃(TPOTM-聚乙烯、聚丙烯、嵌段共聚物聚丙烯(BCPP)或橡胶的聚合物/填料共聚物)、聚酯、聚碳酸酯、聚乙烯基丁酸酯(polyvinylbuterate)、聚氯乙烯、聚乙烯和取代聚乙烯、聚羟基丁酸酯、聚羟基乙烯基丁酸酯、聚醚酰亚胺、聚酰胺、聚萘二甲酸乙二酯、聚酰亚胺、聚醚、聚砜、聚乙烯基乙炔、透明热塑性塑料、透明聚丁二烯、聚氰基丙烯酸酯、纤维素基聚合物、聚丙烯酸酯和聚甲基丙烯酸酯、聚乙烯醇、聚硫化物、聚乙烯醇缩丁醛、聚甲基丙烯酸甲酯、聚硅氧烷、其相容的混合物或者其相容的组合。在一些实施方式中，聚合物材料可作为预聚物或预配混物沉积或涂覆，然后转化。这种聚合物材料包含例如环氧树脂、聚氨酯、酚醛树脂、蜜胺-甲醛树脂、其相容的混合物或其相容的组合。
在一些实施方式中，非玻璃基材202的厚度(例如，第一表面208与第二表面210之间的距离)为至少约1mm，至少约2mm，至少约3mm，至少约4mm，至少约5mm，至少约6mm，至少约7mm，至少约8mm，至少约9mm，或至少约10mm。作为附加或替代形式，非玻璃基材202的厚度为至多约30mm，至多约29mm，至多约28mm，至多约27mm，至多约26mm，至多约25mm，至多约24mm，至多约23mm，至多约22mm，至多约21mm，或至多约20mm。
在多种实施方式中，玻璃片204由玻璃材料、陶瓷材料、玻璃陶瓷材料或其组合形成，或者包含玻璃材料、陶瓷材料、玻璃陶瓷材料或其组合。玻璃片204可利用下拉法(例如熔合下拉法)形成。当与通过其他方法生产的玻璃片相比时，利用熔合下拉法生产的玻璃片具有平坦度和光滑度优良的平面。美国专利第3,338,696号和第3,682,609号描述了熔合法，它们各自通过参考完整地纳入本文。可用来生产玻璃片2014的其他合适的玻璃片形成方法包括浮法、上拉法、轧制法和狭缝拉制法。
在一些实施方式中，玻璃片204具有抗微生物性能。例如，玻璃片204在玻璃片表面具有一定的银离子浓度(例如在大于0至0.047μg/cm2的范围内)，如美国专利申请公开第2012/0034435号所述，其通过参考完整地纳入本文。作为附加或替代形式，玻璃片204涂覆有包含银的釉，或者用银离子掺杂，以显示抗微生物性能，如美国专利申请公开第2011/0081542号所述，其通过参考完整地纳入本文。在一些实施方式中，玻璃片204包含约50mol％的SiO2、约25mol％的CaO和约25mol％的Na2O，以显示抗微生物性能。
在一些实施方式中，玻璃片204的厚度(例如，第一表面212与第二表面214之间的距离)为至少约0.01mm，至少约0.02mm，至少约0.03mm，至少约0.04mm，至少约0.05mm，至少约0.06mm，至少约0.07mm，至少约0.08mm，至少约0.09mm，或至少约0.1mm。作为附加或替代形式，玻璃片204的厚度为至多约3mm，至多约2mm，至多约1mm，至多约0.7mm，至多约0.5mm,至多约0.3mm，至多约0.2mm，或者至多约0.1mm。在一些实施方式中，玻璃片204是柔性玻璃片。例如，玻璃片204的厚度为至多约0.3mm。
在多种实施方式中，粘合剂206由以下物质形成或包含以下物质：粘合剂片或粘合剂膜，液体粘合剂，粉末粘合剂，压敏粘合剂，可紫外光(UV)固化粘合剂，可热固化粘合剂，或其组合。例如，粘合剂206包含低温粘合剂材料，如诺兰(Norland)光学粘合剂68(诺兰产品股份公司)、FLEXcon V29TT粘合剂、3MTM光学透明粘合剂(OCA)8211,8212,8214,8215,8146,8171或8172(在室温或更高温度通过压力粘结)、3MTM 4905胶带、
Figure BDA0001981701760000081
粘合剂、Graphicmount或Facemount[雷杰(LexJet)公司]、硅酮、丙烯酸酯、光学透明粘合剂、包封剂材料、聚氨酯、聚乙烯醇缩丁醛、乙烯-乙酸乙烯酯、离聚物或木胶。另外，例如，粘合剂206包含更高温度的粘合剂材料，如杜邦
Figure BDA0001981701760000082
杜邦PV 5411、日本世界公司(Japan WorldCorporation)材料FAS或聚乙烯醇缩丁醛树脂。在一些实施方式中，粘合剂206包含功能组分，所述功能组分显示出例如颜色、装饰性、耐热性或耐UV性、IR过滤性能或其组合。作为附加或替代形式，粘合剂206固化后是光学透明的、半透明的或不透明的。在粘合剂206为粘合剂片或粘合剂膜的实施方式中，粘合剂可包含透过玻璃片204可见的装饰性图案或设计。
在一些实施方式中，粘合剂206的厚度(例如，在非玻璃基材202的第一表面208与玻璃片204的第二表面214之间)为至多约5000μm，至多约1000μm，至多约500μm，至多约250μm，至多约50μm，至多约40μm，至多约30μm，或至多约25μm。作为附加或替代形式，粘合剂206的厚度为至少约5μm，至少约10μm，至少约15μm，或至少约20μm。在一些实施方式中，粘合剂206的厚度在约5μm与约500μm之间。
在多种实施方式中，粘合剂222可如本文就粘合剂206所述进行配置。粘合剂206和粘合剂222可由相同或不同材料形成或者包含相同或不同材料，并且可具有相同或不同的厚度。
在一些实施方式中，阻挡膜220是多层阻挡膜。在这样的实施方式中，阻挡膜220包含粘合在一起的多个独立的层。例如，独立的层彼此粘合在一起而不熔合。因此，独立的层保持独立，而不是变成熔合的整体式结构，如HPL或LPL结构。在一些实施方式中，阻挡膜220包含金属层和聚合物层。例如，图4中的插图显示了多层阻挡膜的一个实施方式，所述多层阻挡膜包含5个独立的层、基本上由5个独立的层组成或者由5个独立的层组成。多层阻挡膜包含金属层228和多个聚合物层。金属层228是铝箔。多个聚合物层包含PET膜230、PE膜232和线性低密度聚乙烯(LLDPE)膜234。独立的层可利用粘合剂、通过加热和/或加压或者通过其他合适的成膜方法粘合到一起，形成膜。金属层228设置在PE膜232之间，使得金属层被包封在多层阻挡膜220内。金属层的这种包封可有助于防止金属层受到物理破坏和/或暴露于对金属层的阻挡性能可能有不利影响的环境。因此，多层阻挡膜可表现出低WVTR，使玻璃层合物200具有改进的平坦度，同时聚合物层提供耐久性外表面。
在一些实施方式中，金属层由金属材料形成或包含金属材料。例如，金属材料选自下组，该组由以下各项组成：铝、铜、锡、金、铁、钛及其组合。在一些实施方式中，金属层由金属氧化物材料形成或包含金属氧化物材料。例如，金属氧化物材料选自下组，该组由以下各项组成：铝、铜、铟、锡、金、铁、钛、锌、硅及其组合的氧化物。作为附加或替代形式，金属层具有约20nm至约50μm的厚度。例如，金属层是金属箔或者金属氧化物层(例如利用沉积方法沉积在聚合物层上，所述沉积方法是例如物理或化学气相沉积、原子层沉积或其他沉积方法)。
在一些实施方式中，聚合物层包含多个聚合物层。在一些这样的实施方式中，金属层设置在所述多个聚合物层中的两个聚合物层之间。因此，金属层基本上或完全被包封在聚合物层内。在一些实施方式中，聚合物层包含选自下组的材料，该组由以下各项组成：聚对苯二甲酸乙二酯(PET)、聚乙烯(PE)、线性低密度聚乙烯(LLDPE)、聚丙烯酸酯、尼龙、其相容的混合物及其相容的组合。多层阻挡膜可如本文所述提供低WVTR，从而能够改善平坦度，同时为玻璃层合物提供耐久性外表面。
在一些实施方式中，阻挡膜220是透明的。例如，阻挡膜220在400-750nm的波长范围内具有至少约70％，至少约75％，至少约80％，至少约85％，至少约90％，至少约95％，至少约98％，或至少约99％的平均透光率。在一些实施方式中，金属氧化物可用作透明阻挡膜中的金属层。在一些实施方式中，阻挡膜220和粘合剂222是透明的，使得非玻璃基材202透过阻挡膜和粘合剂是可见的。在一些这样的实施方式中，非玻璃基材202包含装饰(例如在第二表面210处)，该装饰透过阻挡膜220和粘合剂222是可见的。在其他实施方式中，阻挡膜220是透明的，而粘合剂222包含透过阻挡膜220可见的装饰。在其他实施方式中，阻挡膜220包含装饰层(例如，聚合物层中的一个或多个层)，该装饰层从玻璃层合物200的外表面是可见的。
尽管图4所示的多层阻挡膜是5层阻挡膜，但本公开包含其他实施方式。在其他实施方式中，多层阻挡膜包含预定数量的层(例如2,3,4或更多层)，基本上由该预定数量的层组成，或者由该预定数量的层组成。在一些实施方式中，多层阻挡膜包含设置在相邻层之间的粘合剂。
在一些实施方式中，阻挡膜220是单层阻挡膜。例如，阻挡膜220由金属层形成，包含金属层，基本上由金属层组成，或者由金属层组成。金属层可如本文就多层阻挡膜所述进行配置。
在一些实施方式中，阻挡膜220不含或基本上不含玻璃片材料。例如，阻挡膜220可包含玻璃、玻璃陶瓷和/或陶瓷材料作为第二组分(例如填料)。不过，在这样的实施方式中，阻挡膜220不含玻璃片、玻璃陶瓷片或陶瓷片(例如实心或基本上实心的片材，不同于纤维垫或编织物)。在其他实施方式中，阻挡膜220包含玻璃片材料。尽管这种玻璃片材料显示出低WVTR，因而能够改善平坦度，但包含这种含玻璃片材料的阻挡膜的玻璃层合物会难于制造、切割以及在制造过程中操作、运输和/或安装。
在一些实施方式中，阻挡膜220的厚度(例如，在第一表面224与第二表面226之间)为至多约0.5mm，至多约0.4mm，至多约0.3mm，至多约0.2mm，或至多约0.1mm。作为附加或替代形式，阻挡膜220的厚度为至少约0.01mm，至多约0.02mm，至多约0.03mm，至多约0.04mm，或至多约0.05mm。
在多种实施方式中，在45℃测定并根据ASTM F1249-13确定，阻挡膜220所具有的WVTR为至多约2g/m2/日，至多约1g/m2/日，至多约0.9g/m2/日，至多约0.8g/m2/日，至多约0.7g/m2/日，至多约0.6g/m2/日，至多约0.5g/m2/日，至多约0.4g/m2/日，至多约0.3g/m2/日，至多约0.2g/m2/日，或至多约0.1g/m2/日。在一些实施方式中，阻挡膜220在45℃测定的WVTR为玻璃片204在45℃测定的水分透过率的至多约100,000倍，至多约10,000倍，至多约1,000倍，或至多约100倍。例如，据报告，在45℃测定并根据ASTM F1249-13确定，
Figure BDA0001981701760000101
玻璃具有<7x 10-6g/m2/日的WVTR。
在多种实施方式中，在45℃测定并根据ASTM E398-13确定，阻挡膜220所具有的WVTR为至多约2g/m2/日，至多约1g/m2/日，至多约0.9g/m2/日，至多约0.8g/m2/日，至多约0.7g/m2/日，至多约0.6g/m2/日，至多约0.5g/m2/日，至多约0.4g/m2/日，至多约0.3g/m2/日，至多约0.2g/m2/日，或至多约0.1g/m2/日。在一些实施方式中，阻挡膜220在45℃测定的WVTR为玻璃片204在45℃测定的水分透过率的至多约100,000倍，至多约10,000倍，至多约1,000倍，或至多约100倍。例如，据报告，在45℃测定并根据ASTM E398-13确定，
Figure BDA0001981701760000111
玻璃具有<7x 10-6g/m2/日的WVTR。
在一些实施方式中，在23℃和90％相对湿度经历7天后，根据欧洲标准EN 438测定的玻璃层合物200的平坦度绝对值为至多约10mm/m，至多约9mm/m，至多约8mm/m，至多约7mm/m，至多约6mm/m，至多约5mm/m，至多约4mm/m，至多约3mm/m，至多约2mm/m，至多约1.5mm/m，至多约1.2mm/m，至多约1.1mm/m，至多约1mm/m，至多约0.9mm/m，至多约0.8mm/m，至多约0.7mm/m，至多约0.6mm/m，或至多约0.5mm/m。作为附加或替代形式，在23℃和90％相对湿度经历7天后，根据欧洲标准EN 438测定的玻璃层合物200的平坦度变化的绝对值为至多约10mm/m，至多约9mm/m，至多约8mm/m，至多约7mm/m，至多约6mm/m，至多约5mm/m，至多约4mm/m，至多约3mm/m，至多约2mm/m，至多约1.5mm/m，至多约1.2mm/m，至多约1.1mm/m，至多约1mm/m，至多约0.9mm/m，至多约0.8mm/m，至多约0.7mm/m，至多约0.6mm/m，或至多约0.5mm/m。
在一些实施方式中，形成玻璃层合物200的方法包括将玻璃片204层合至非玻璃基材202的第一表面208。例如，将玻璃片204层合至第一表面208包括将粘合剂206施涂至玻璃片的第二表面214和/或非玻璃基材202的第一表面208，并通过该粘合剂将玻璃片与非玻璃基材接合起来。因此，层合之后，玻璃片204粘合至玻璃基材202，而不是整合至或嵌埋在非玻璃基材中。层合可利用合适的层合方法进行，如辊压层合法、高压釜层合法或真空层合法。
在一些实施方式中，所述方法包括将阻挡膜220层合至非玻璃基材的第二表面210。例如，将阻挡膜220层合至第二表面210包括将粘合剂222施涂至阻挡膜的第一表面224和/或非玻璃基材202的第二表面210，并通过该粘合剂将阻挡膜与非玻璃基材接合起来。因此，层合之后，阻挡膜220粘合至玻璃基材202，而不是整合至或嵌埋在非玻璃基材中。将阻挡膜220层合至非玻璃基材202可在将玻璃片204层合至非玻璃基材之前、之后或同时进行。
在一些实施方式中，所述方法还包括在层合玻璃片204和阻挡膜220之前形成非玻璃基材202。例如，形成非玻璃基材202包括压制一堆聚合物浸渍纸，以粘接所述聚合物浸渍纸。在一些这样的实施方式中，压制该堆聚合物浸渍纸包括HPL法或LPL法。
在一些实施方式中，在层合阻挡膜220之后，阻挡膜的第一表面224与非玻璃基材202相邻，阻挡膜的与该第一表面相反的第二表面226限定玻璃层合物200的外表面。因此，玻璃层合物200不含层合至阻挡膜220的第二表面226的附加层或材料。
实施例
下面将结合实施例进一步说明各种实施方式。
实施例1
形成具有如图4所示一般构造的玻璃层合物。非玻璃基材是8mm厚的HPL板，其具有嵌埋在装饰性表面层下方的40μm厚铝层，所述装饰性表面层设置在非玻璃基材的每个外表面处，该非玻璃基材可以是ABET股份公司[美国新泽西州恩格尔伍德市(Englewood)]销售的材料外用级(MEG)板。玻璃片是厚0.2mm的柔性铝硅酸盐玻璃片，可以是康宁股份公司(美国纽约州康宁市)销售的
Figure BDA0001981701760000121
玻璃。阻挡膜是厚30μm的铝箔。利用3M公司[美国明尼苏达州梅普尔伍德市(Maplewood)]以3MTM光学透明粘合剂8215销售的光学透明粘合剂将玻璃片和阻挡膜各自层合至非玻璃基材。搭接剪切粘合力为1.18MPa。
层合过程包括用胶辊将粘合剂施涂至非玻璃基材的第一表面，然后将玻璃片施加至非玻璃基材的覆有粘合剂的第一表面。用胶辊将粘合剂施涂至非玻璃基材的第二表面，然后将阻挡膜施加至非玻璃基材的覆有粘合剂的第二表面。
实施例2
形成具有如图4所示一般构造的玻璃层合物。非玻璃基材是具有实施例1中所述构造的HPL板。玻璃片是如实施例1所述的柔性铝硅酸盐玻璃片。阻挡膜是厚100μm的钢片。如实施例1所述用粘合剂将玻璃片和阻挡膜各自层合至非玻璃基材。
实施例3
形成具有如图4所示一般构造的玻璃层合物。非玻璃基材是具有实施例1中所述构造的HPL板。玻璃片是如实施例1所述的柔性铝硅酸盐玻璃片。阻挡膜是厚0.2mm的柔性铝硅酸盐玻璃片。如实施例1所述用粘合剂将玻璃片和阻挡膜各自层合至非玻璃基材。
实施例4
形成具有如图4所示一般构造的玻璃层合物。非玻璃基材是具有实施例1中所述构造的HPL板。玻璃片是如实施例1所述的柔性铝硅酸盐玻璃片。阻挡膜是多层阻挡膜，其按照从外表面朝向非玻璃基材的顺序包含以下各层：PET(12μm)、PE(20μm)、铝箔(6μm)、PE(20μm)、LLDPE(35μm)。阻挡膜的WVTR<0.1g/m2/日。如实施例1所述用粘合剂将玻璃片和阻挡膜各自层合至非玻璃基材。
实施例5
形成具有如图4所示一般构造的玻璃层合物。非玻璃基材是具有实施例1中所述构造的HPL板。玻璃片是如实施例1所述的柔性铝硅酸盐玻璃片。阻挡膜是多层阻挡膜，其按照从外表面朝向非玻璃基材的顺序包含以下各层：尼龙(15μm)、铝箔(7μm)、PE(78μm)。阻挡膜的WVTR<0.1g/m2/日。如实施例1所述用粘合剂将玻璃片和阻挡膜各自层合至非玻璃基材。
实施例6
形成具有如图4所示一般构造的玻璃层合物。非玻璃基材是具有实施例1中所述构造的HPL板。玻璃片是如实施例1所述的柔性铝硅酸盐玻璃片。阻挡膜是多层阻挡膜，其按照从外表面朝向非玻璃基材的顺序包含以下各层：丙烯酸涂层、PE(38μm)、丙烯酸涂层、铝(40-80μm)。阻挡膜的WVTR<1.5g/m2/日。如实施例1所述用粘合剂将玻璃片和阻挡膜各自层合至非玻璃基材。
实施例7
形成具有如图4所示一般构造的玻璃层合物。非玻璃基材是具有实施例1中所述构造的HPL板。玻璃片是如实施例1所述的柔性铝硅酸盐玻璃片。阻挡膜是多层阻挡膜，其按照从外表面朝向非玻璃基材的顺序包含以下各层：PET(50μm)、铝箔(7μm)、PET(50μm)、丙烯酸丙烯酸酯压敏粘合剂(50μm)。阻挡膜的WVTR<0.05g/m2/日。如实施例1所述用粘合剂将玻璃片层合至非玻璃基材。利用整合在阻挡膜中的丙烯酸丙烯酸酯压敏粘合剂将阻挡膜层合至非玻璃基材。
实施例8
形成具有如图4所示一般构造的玻璃层合物。非玻璃基材是具有实施例1中所述构造的HPL板。玻璃片是如实施例1所述的柔性铝硅酸盐玻璃片。阻挡膜是多层阻挡膜，其按照从外表面朝向非玻璃基材的顺序包含以下各层：PET(100μm)、氧化硅(1μm)。阻挡膜的WVTR<0.01g/m2/日。如实施例1所述用粘合剂，将玻璃片和阻挡膜各自层合至非玻璃基材。
比较例1
形成具有如图1所示一般构造的玻璃层合物。非玻璃基材是不含任何嵌埋铝层的HPL板。玻璃片是如实施例1所述的柔性铝硅酸盐玻璃片。玻璃层合物不含阻挡膜。如实施例1所述用粘合剂将玻璃片层合至非玻璃基材。
比较例2
形成具有如图1所示一般构造的玻璃层合物。非玻璃基材是具有实施例1中所述构造的HPL板。玻璃片是如实施例1所述的柔性铝硅酸盐玻璃片。玻璃层合物不含阻挡膜。如实施例1所述用粘合剂将玻璃片层合至非玻璃基材。
表1显示了各实施例、比较例和出厂的不含层合至其上的玻璃片或阻挡膜的HPL基材按照欧洲标准EN 438测定的平坦度，以及在23℃和90％相对湿度经历7天后按照欧洲标准EN 438测定的相比于出厂平坦度的平坦度变化。应当指出，表1中所示的比较例2的平坦度“＜-15”是指该样品在负方向上显示出超过15mm/m的弯曲。因此，弯曲的绝对值大于15mm/m。
表1：玻璃层合物和HPL基材的平坦度或平坦度变化
Figure BDA0001981701760000151
表1所示数据证实，与比较例1-2中没有阻挡层的玻璃层合物相比，实施例1-8中有阻挡膜层合至与玻璃片相反的非玻璃基材表面的玻璃层合物显示出改善的平坦度。
令人吃惊的是，即使比较例2的玻璃层合物包含嵌埋在非玻璃基材中的铝层，与该比较例2的玻璃层合物相比，实施例1-8中有阻挡膜层合至与玻璃片相反的非玻璃基材表面的玻璃层合物仍然显示出改善的平坦度。无意受限于任何理论，据信，尽管嵌埋的铝层可以基本上防止水分在非玻璃基材中更深地渗透到铝层以外，但即使少量聚合物浸渍纸(例如苯酚浸渍装饰性层和蜜胺浸渍覆层)远离玻璃片设置在铝层与玻璃层合物外表面之间，也能吸收足量的水分，造成玻璃层合物弯曲。
对本领域技术人员显而易见的是，在不背离要求权利的主题的精神或范围的情况下，可以做出各种改进和变化。因此，除了所附权利要求及其等同要求之外，要求权利的主题不受限制。

Claims (24)

1.一种玻璃层合物，包含：
包含第一表面和与该第一表面相反的第二表面的非玻璃基材；
层合至非玻璃基材的第一表面的玻璃片；以及
层合至非玻璃基材的第二表面的阻挡膜，所述阻挡膜包含与非玻璃基材相邻的第一表面和与该第一表面相反的第二表面，并具有至多0.5mm的厚度，其中阻挡膜是：
(i)单层阻挡膜，且阻挡膜由金属层组成；或者
(ii)多层阻挡膜，其包含金属层和聚合物层，
其中金属层具有20nm至50μm的厚度，
其中阻挡膜的第二表面限定玻璃层合物的外表面。
2.根据权利要求1所述的玻璃层合物，其中金属层包含选自下组的金属材料，该组由以下各项组成：铝、铜、锡、金、铁、钛及其组合。
3.根据权利要求1所述的玻璃层合物，其中金属层包含选自下组的金属氧化物材料，该组由以下各项组成：铜、金、铁、钛、锌及其组合的氧化物。
4.根据权利要求1所述的玻璃层合物，其中聚合物层包含多个聚合物层。
5.根据权利要求4所述的玻璃层合物，其中金属层设置在所述多个聚合物层中的两个聚合物层之间。
6.根据权利要求1所述的玻璃层合物，其中聚合物层包含选自下组的聚合物材料，该组由以下各项组成：聚对苯二甲酸乙二酯(PET)、聚乙烯(PE)、线性低密度聚乙烯(LLDPE)、聚丙烯酸酯、尼龙、其相容的混合物及其相容的组合。
7.根据权利要求1所述的玻璃层合物，其中阻挡膜是透明的。
8.根据权利要求1所述的玻璃层合物，其中阻挡膜是单层阻挡膜。
9.根据权利要求8所述的玻璃层合物，其中阻挡膜由金属层组成。
10.根据权利要求1所述的玻璃层合物，其中玻璃片是厚度至多0.3mm的柔性玻璃片。
11.根据权利要求1所述的玻璃层合物，其中非玻璃基材包含多张聚合物浸渍纸。
12.根据权利要求1所述的玻璃层合物，其中非玻璃基材选自下组，该组由以下各项组成：高压层合(HPL)板、低压层合(LPL)板、木质人造板、聚合物板及其组合。
13.根据权利要求1所述的玻璃层合物，其中在23℃和90％相对湿度下经历7天后，玻璃层合物按照欧洲标准EN 438测定的平坦度绝对值为至多3mm/m。
14.根据权利要求1所述的玻璃层合物，其中在23℃和90％相对湿度下经历7天后，玻璃层合物按照欧洲标准EN 438测定的平坦度变化的绝对值为至多2mm/m。
15.一种玻璃层合物，包含：
包含第一表面和与该第一表面相反的第二表面的非玻璃基材；
层合至非玻璃基材的第一表面的玻璃片；以及
层合至非玻璃基材的第二表面的多层阻挡膜，所述多层阻挡膜包含金属层和聚合物层；
其中在23℃和90％相对湿度下经历7天后，玻璃层合物按照欧洲标准EN 438测定的平坦度绝对值为至多3mm/m。
16.根据权利要求15所述的玻璃层合物，其中多层阻挡膜具有至多2g/m2/日的水蒸气透过率。
17.据权利要求15所述的玻璃层合物，其中：
聚合物层包含多个聚合物层；以及
金属层设置在所述多个聚合物层中的两个聚合物层之间。
18.根据权利要求15所述的玻璃层合物，其中玻璃片是厚度至多0.3mm的柔性玻璃片。
19.根据权利要求15所述的玻璃层合物，其中非玻璃基材包含多张聚合物浸渍纸。
20.一种形成玻璃层合物的方法，所述方法包括：
将玻璃片层合至非玻璃基材的第一表面；
将阻挡膜层合至非玻璃基材的第二表面，其中阻挡膜是：
(i)单层阻挡膜，且阻挡膜由金属层组成；或者
(ii)多层阻挡膜，其包含金属层和聚合物层，
其中金属层具有20nm至50μm的厚度。
21.根据权利要求20所述的方法，还包括在分别层合玻璃片和层合多层阻挡膜之前，通过压制一堆聚合物浸渍纸来粘接该聚合物浸渍纸，由此形成非玻璃基材。
22.根据权利要求21所述的方法，其中压制该堆聚合物浸渍纸包括高压层合(HPL)法或低压层合(LPL)法。
23.根据权利要求20所述的方法，其中在层合多层阻挡膜之后，多层阻挡膜的第一表面与非玻璃基材相邻，多层阻挡膜的与该第一表面相反的第二表面限定玻璃层合物的外表面。
24.根据权利要求20所述的方法，其中在23℃和90％相对湿度下经历7天后，玻璃层合物按照欧洲标准EN 438测定的平坦度绝对值为至多3mm/m。
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US11872785B2 (en) 2024-01-16
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US11247435B2 (en) 2022-02-15
US20220134711A1 (en) 2022-05-05
KR102095935B1 (ko) 2020-04-01
EP3507090A4 (en) 2020-04-29
CN110049865A (zh) 2019-07-23
WO2018044082A1 (en) 2018-03-08
CA3035340A1 (en) 2018-03-08

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