CN112456811A - 一种镀膜玻璃及其夹层玻璃 - Google Patents

一种镀膜玻璃及其夹层玻璃 Download PDF

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Publication number
CN112456811A
CN112456811A CN202011292551.1A CN202011292551A CN112456811A CN 112456811 A CN112456811 A CN 112456811A CN 202011292551 A CN202011292551 A CN 202011292551A CN 112456811 A CN112456811 A CN 112456811A
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China
Prior art keywords
transparent conductive
glass plate
conductive film
film
layer
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Granted
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CN202011292551.1A
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CN112456811B (zh
Inventor
屠乐乐
刘贤平
关金亮
王辉
陈志新
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Fuyao Glass Industry Group Co Ltd
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Fuyao Glass Industry Group Co Ltd
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Abstract

本发明涉及玻璃产品领域,特别是安装在车辆上的窗玻璃,具体地提供一种镀膜玻璃及其夹层玻璃。所述镀膜玻璃包括弯曲玻璃板和透明导电膜,在所述透明导电膜中设置有至少一个除膜区域,所述透明导电膜包括至少一个金属层和/或金属合金层,所述弯曲玻璃板和所述透明导电膜通过将沉积有透明导电膜的平直玻璃板经过至少560℃的高温热处理和弯曲成型获得,所述弯曲玻璃板的可见光透过率减去所述除膜区域的可见光透过率小于或等于5%,所述除膜区域的雾度减去所述弯曲玻璃板的雾度小于或等于2%。本发明能够得到型面质量好、光畸变小的镀膜玻璃,进一步改善了镀膜玻璃和夹层玻璃的反射变形、天线信号透过和相机光谱特性。

Description

一种镀膜玻璃及其夹层玻璃
技术领域:
本发明涉及玻璃产品领域,特别是安装在车辆上的窗玻璃,具体地提供一种用于激光除膜的印刷组合物以及利用该印刷组合物制造的镀膜玻璃,还提供一种包括该镀膜玻璃的夹层玻璃及其制造方法。
背景技术:
利用化学气相沉积技术(CVD)或物理气相沉积技术(PVD)在玻璃基板的表面上沉积透明导电膜形成的镀膜玻璃已经被广泛地应用在车辆和建筑上,基于透明导电膜中的金属层、金属合金层或透明导电氧化物层的良好导电性和能够反射红外线的特性,使这样的镀膜玻璃具有电加热功能和/或隔热功能,例如中国专利CN1093346A、CN1108862A、CN101304955A、CN111247108A、CN104039732B、CN107709265A、CN107810170A和CN111566063A等,能够实现除霜除雾、日光控制(防晒或遮阳)、低辐射等用途。
将镀膜玻璃应用到车辆上,特别是用作前挡风玻璃时,通常还在玻璃上位于车内的一侧装配有ETC(电子不停车收费系统)、RFID(射频识别)、雨感器、照相机和激光雷达等电子设备,而由于透明导电膜自身对电磁波具有屏蔽作用,从而会影响这些电子设备与车外进行无线数据交换,其中ETC系统就是通过安装在前挡风玻璃的内表面上的车载单元(OBU)与安装在收费站车道上的路侧单元(RSU)进行双向通讯以实现数据交换,这就需要在透明导电膜中设置除膜区域(即无透明导电膜区域)作为数据窗口,例如专利EP1274597B1公开了在透明导电层中设置至少两个间隔开的数据传输窗口(即无透明导电层区域),又例如专利US6559419公开了在可加热涂层中设置一个涂层去除区域以用作收费装置和/或雨水传感器容易地发送和/或接收信号,还有专利CN102474912A、CN102450093A、CN102640562A和CN106797679B也都公开了在导电涂层中设置一个或两个不含导电涂层的透明区域作为数据传输窗口。
为了在透明导电膜中形成无透明导电膜区域以作为数据传输窗口,可以在将透明导电膜沉积到玻璃基板的表面上时通过盖板掩蔽来实现,也可以在将透明导电膜沉积到玻璃基板的表面上后通过机械剥离、化学剥蚀和/或激光除膜等技术来实现,专利US5131967公开了利用激光去除玻璃基板的表面上的透明导电膜的外围部分,为了避免激光损坏玻璃基板,需要控制除膜时间和激光的功率水平;专利EP2325002B1公开了利用激光去除PET薄膜上的局部金属涂层以形成剥离区域,在剥离区域中,去除了至少80重量%,优选至少90重量%的原始金属涂层,也就是说,剥离区域中的金属涂层可能未被完全去除。
目前,车辆上安装的窗玻璃均由1片或2片弯曲玻璃板构成,该弯曲玻璃板通常由被加热软化的平直玻璃板经过重力弯曲成型工艺或压制弯曲成型工艺形成,平直玻璃板被加热的方式主要是在加热炉内通过加热元件对玻璃表面进行热辐射;而与玻璃板相比,透明导电膜对热辐射具有更高的反射和更低的吸收,如果平直玻璃板上的透明导电膜在被加热弯曲成型前形成无透明导电膜区域,那么在接下来的被加热软化的过程中,平直玻璃板上的无透明导电膜区域的温度比覆盖有透明导电膜的区域的温度更高,甚至在平直玻璃板的不同区域形成几十或上百摄氏度的温度梯度,导致在后续的弯曲成型过程中存在动力学差异,使最终得到的弯曲玻璃板局部光学失真,特别是无透明导电膜区域及其边界区域更为明显,因此可能会带来与设计的形状匹配性差、在视野区域产生透视变形、导致摄像头通过无透明导电膜区域获取的图像不能满足要求等问题。
为了解决上述先在透明导电膜中形成无透明导电膜区域然后再被加热软化的工艺存在的问题,本领域技术人员考虑先将平直玻璃板加热弯曲成型为弯曲玻璃板然后再在弯曲玻璃板上的透明导电膜中形成无透明导电膜区域,例如专利CN108124434A公开了一种用于制造玻璃层的结构化的功能涂层的方法,借助激光烧灼将在弯曲玻璃层上的功能涂层的一些部分剥蚀,并且该功能涂层在玻璃板弯曲之后施加,这种功能涂层存在镀膜效率低、膜系结构单一、无法满足汽车级使用要求等缺点;针对将透明导电膜沉积到平直玻璃板的表面上后先进行加热弯曲成型再形成无透明导电膜区域的情况,透明导电膜要和平直玻璃板一起经受至少560℃甚至600℃以上的高温,透明导电膜的部分膜层在高温下与玻璃板表面发生相互作用,表现为透明导电膜的部分膜层与玻璃板的表面相互结合甚至产生渗透,对于表面粗糙度更大的陶瓷油墨层来说,其表面上沉积的透明导电膜在高温下与陶瓷油墨层的表面相互结合地更牢或渗透地更深,这就使得要作为数据传输窗口的区域的透明导电膜无法彻底去除干净,带来可见光透过率降低、雾度较高、外观发白甚至出现阴影等缺陷,如果一定要彻底去除干净,则必然会破坏玻璃板或陶瓷油墨层。
发明内容:
本发明所要解决的技术问题是针对将透明导电膜沉积到平直玻璃板的表面上后先进行加热弯曲成型再利用激光除膜技术形成无透明导电膜区域时存在无法彻底去除局部的透明导电膜或必然破坏玻璃板和陶瓷油墨层等缺点,提供一种镀膜玻璃及其夹层玻璃,还提供一种用于激光除膜的印刷组合物和夹层玻璃的制造方法。
本发明解决其技术问题所采取的技术方案是:一种镀膜玻璃,包括弯曲玻璃板和透明导电膜,所述透明导电膜沉积在所述弯曲玻璃板的至少一个表面上,在所述透明导电膜中设置有至少一个除膜区域,所述除膜区域内没有覆盖透明导电膜,其特征在于:所述透明导电膜包括至少一个金属层和/或金属合金层,所述弯曲玻璃板和所述透明导电膜通过将沉积有透明导电膜的平直玻璃板经过至少560℃的高温热处理和弯曲成型获得,所述弯曲玻璃板的可见光透过率减去所述除膜区域的可见光透过率小于或等于5%,所述除膜区域的雾度减去所述弯曲玻璃板的雾度小于或等于2%。
优选地,所述金属层选用金、银、铜、铝或钼,所述金属合金层为银合金。
优选地,所述金属层和/或金属合金层的金属粒子在所述除膜区域内的数量等于0。
优选地,所述透明导电膜包括至少一个银层和/或银合金层,每个银层或银合金层位于至少两个介质层之间,所述介质层的材料选自锌、镁、锡、钛、铌、锆、镍、铟、硅、铝、铈、钨、钼、锑、铋元素的氧化物中的至少一种,和/或选自硅、铝、锆、钇、铈、镧元素的氮化物、氮氧化物及其混合物中的至少一种。
优选地,所述弯曲玻璃板上的透明导电膜的方阻比所述平直玻璃板上的透明导电膜的方阻小0~32%。
优选地,所述弯曲玻璃板的可见光透过率减去所述除膜区域的可见光透过率小于或等于1%,所述除膜区域的雾度减去所述弯曲玻璃板的雾度小于或等于0.4%。
优选地,所述弯曲玻璃板的可见光透过率减去所述除膜区域的可见光透过率等于0,所述除膜区域的雾度减去所述弯曲玻璃板的雾度等于0。
优选地,在沉积有所述透明导电膜的所述弯曲玻璃板的表面上还设置有深色油墨层,所述透明导电膜至少部分地覆盖所述深色油墨层,至少一个除膜区域的至少部分位于所述深色油墨层上的透明导电膜中。
更优选地,所述金属层和/或金属合金层的金属粒子在所述深色油墨层内的数量等于0。
优选地,所述深色油墨层的可见光透过率小于或等于1.5%,紫外线透过率小于或等于0.05%,所述深色油墨层的材料选用陶瓷油墨或紫外线干燥油墨。
本发明还提供一种包括所述镀膜玻璃的夹层玻璃,所述夹层玻璃还包括中间粘结层和第二玻璃板,所述中间粘结层将所述镀膜玻璃和所述第二玻璃板粘接在一起。
优选地,所述透明导电膜与所述中间粘结层直接接触。
优选地,所述夹层玻璃还包括与所述透明导电膜直接电接触的第一汇流母线和第二汇流母线,供电电源通过所述第一汇流母线和第二汇流母线向所述透明导电膜内输入电流,所述供电电源能够提供12~60V的供电电压。
优选地,所述第一汇流母线和所述第二汇流母线为导电银浆和/或金属箔,所述金属箔为金箔、银箔、铜箔或铝箔。
优选地,所述第二玻璃板为由平直玻璃板经过至少560℃的高温热处理和弯曲成型形成,或为厚度小于或等于1.1mm的化学钢化玻璃板,或为厚度小于或等于1.1mm的本体强化平直玻璃板。
优选地,所述镀膜玻璃上设置有深色油墨层,所述深色油墨层的至少部分形成点状油墨分散区,所述点状油墨分散区中的透明导电膜部分地覆盖在深色油墨层上、部分地覆盖在弯曲玻璃板的表面上,至少一个除膜区域位于所述点状油墨分散区中。
本发明还提供一种用于激光除膜的印刷组合物,其特征在于:按质量百分比计包括60%~70%无机隔离颗粒、7%~15%树脂添加剂、15%~22%颜料和5%~10%有机溶剂;所述无机隔离颗粒包括硅藻土、晶体硅、石英砂中的至少一种;所述树脂添加剂包括丙烯酸酯;所述颜料包括铁、铜、钴、镍、锰金属的氧化物中的至少一种;所述有机溶剂包括二苯基甲酮和异丙基噻吨酮中的至少一种。
优选地,所述无机隔离颗粒的粒径小于或等于2微米。
优选地,所述印刷组合物能够被印刷到平直玻璃板或陶瓷油墨层的表面上并固化后形成除膜保护层。
更优选地,所述固化的温度小于或等于200℃。
本发明还提供一种夹层玻璃的制造方法,所述夹层玻璃包括镀膜玻璃、中间粘结层和第二玻璃板,所述镀膜玻璃包括弯曲玻璃板和透明导电膜,在所述透明导电膜中设置有至少一个除膜区域,其特征在于,包括以下步骤:
步骤1:准备平直玻璃板,在所述平直玻璃板上设置至少一个除膜保护层;
步骤2:在所述平直玻璃板的设置有除膜保护层的表面上沉积透明导电膜,所述透明导电膜至少部分地覆盖所述除膜保护层;
步骤3:将带有透明导电膜和除膜保护层的平直玻璃板经过至少560℃的高温热处理和弯曲成型,获得弯曲玻璃板;
步骤4:利用激光器产生的激光束去除所述弯曲玻璃板上的所述除膜保护层上的透明导电膜;
步骤5:清除所述弯曲玻璃板上的所述除膜保护层,在所述透明导电膜中形成至少一个除膜区域,获得镀膜玻璃;
步骤6:准备第二玻璃板和至少一片中间粘结层,将所述镀膜玻璃和所述第二玻璃板通过所述至少一片中间粘结层进行合片,获得夹层玻璃。
优选地,所述除膜保护层的厚度为5~20微米,步骤1中的除膜保护层由所述印刷组合物印刷到平直玻璃板的表面上并固化后形成,所述固化的温度小于或等于200℃。
更优选地,所述印刷组合物按质量百分比计包括60%~70%无机隔离颗粒、7%~15%树脂添加剂、15%~22%颜料和5%~10%有机溶剂;所述无机隔离颗粒包括硅藻土、晶体硅、石英砂中的至少一种;所述树脂添加剂包括丙烯酸酯;所述颜料包括铁、铜、钴、镍、锰金属的氧化物中的至少一种;所述有机溶剂包括二苯基甲酮和异丙基噻吨酮中的至少一种。
优选地,步骤1中在所述平直玻璃板的设置有除膜保护层的表面上还设置深色油墨层。
更优选地,所述深色油墨层在所述除膜保护层之前形成在所述平直玻璃板的同一表面上。
更优选地,所述深色油墨层的厚度为15~40微米,所述深色油墨层的厚度大于或等于所述除膜保护层的厚度。
更优选地,所述弯曲玻璃板上的深色油墨层与玻璃板表面之间的结合力大于所述平直玻璃板上的深色油墨层与玻璃板表面之间的结合力。
更优选地,所述透明导电膜至少部分地覆盖所述深色油墨层。
进一步地,至少一个除膜保护层的至少部分位于所述深色油墨层上,所述弯曲玻璃板上的除膜保护层与深色油墨层表面之间的结合力小于所述平直玻璃板上的除膜保护层与深色油墨层表面之间的结合力。
优选地,步骤2中在所述透明导电膜沉积到所述平直玻璃板的表面上之后,还在所述透明导电膜的表面上印刷导电银浆。
优选地,所述弯曲玻璃板上的透明导电的方阻小于所述平直玻璃板上的透明导电膜的方阻。
优选地,所述弯曲玻璃板上的除膜保护层与玻璃板表面之间的结合力小于所述平直玻璃板上的除膜保护层与玻璃板表面之间的结合力。
优选地,所述激光器为红外线激光器或绿光激光器,所述红外线激光器用于产生波长为1053nm或1064nm的激光束,所述绿光激光器用于产生波长为527nm或532nm的激光束。
优选地,所述第二玻璃板为由平直玻璃板经过至少560℃的高温热处理和弯曲成型形成的弯曲玻璃板,或为厚度小于或等于1.1mm的化学钢化平直玻璃板,或为厚度小于或等于1.1mm的本体强化平直玻璃板。
更优选地,所述镀膜玻璃的厚度比所述化学钢化平直玻璃板的厚度或所述本体强化平直玻璃板的厚度大至少0.7mm,所述化学钢化平直玻璃板或所述本体强化平直玻璃板通过冷成型工艺实现与所述镀膜玻璃的粘合并最终弯曲成型。
本发明由于采取了上述技术方案,其具有如下有益效果:
本发明采用的用于激光除膜的印刷组合物,能够在透明导电膜中形成除膜区域的过程中保护玻璃板或深色油墨层,在将除膜区域内的透明导电膜全部去除的同时,还避免玻璃板或深色油墨层在激光除膜过程中被破坏,而且具有良好的热传导性和耐热性,不会对平直玻璃板的加热软化和弯曲成型过程产生影响,能够得到型面质量好、光畸变小的镀膜玻璃,进一步改善了利用该印刷组合物制造的镀膜玻璃和夹层玻璃的反射变形、天线信号透过和相机光谱特性。
附图说明:
图1为本发明所述的镀膜玻璃的俯视示意图;
图2为本发明所述的镀膜玻璃的剖视示意图;
图3为本发明所述的深色油墨层上具有除膜区域的局部放大示意图;
图4为本发明所述的深色油墨层上具有除膜区域的局部剖视示意图;
图5为本发明所述的夹层玻璃的剖视示意图;
图6a为本发明所述的弯曲玻璃板的表面上具有透明导电膜和除膜保护层的局部剖视图;
图6b为图6a中的弯曲玻璃板上的除膜保护层上的透明导电膜被去除后的结构示意图;
图6c为图6b中的弯曲玻璃板上的除膜保护层被清除后的镀膜玻璃的结构示意图;
图7a为本发明所述的深色油墨层的表面上具有透明导电膜和除膜保护层的局部剖视图;
图7b为图7a中的深色油墨层上的除膜保护层上的透明导电膜被去除后的结构示意图;
图7c为图7b中的深色油墨层上的除膜保护层被清除后的镀膜玻璃的结构示意图。
具体实施方式:
以下结合附图对本发明的内容作进一步说明。
如图1和图2所示,本发明所述的镀膜玻璃100包括弯曲玻璃板1和透明导电膜2,所述透明导电膜2沉积在所述弯曲玻璃板1的至少一个表面上,在所述透明导电膜2中设置有至少一个除膜区域101,所述除膜区域101用作电子设备的无线数据的传输窗口,能够实现通信数据、图像数据和传感器数据等无障碍地穿过所述镀膜玻璃100,所述电子设备可以举例为雨感器、摄像机、激光雷达、ETC天线、RFID天线等。在图1中,本发明具体示出了四个除膜区域101,其中两个大致呈平行四边形的除膜区域101可以作为ETC天线数据窗口,中间一个大致呈梯形的除膜区域101可以作为摄像机数据窗口,下侧大致呈圆形的除膜区域101可以作为雨感器数据窗口。其中,所述除膜区域101的至少部分边界由所述透明导电膜2限定,图1中的四个除膜区域101的四周边界由所述透明导电膜2限定;当然,当部分除膜区域101靠近所述透明导电膜2的外边界时,除膜区域101可以呈现为靠近所述透明导电膜2的外边界的缺口形状,即除膜区域101的三边由所述透明导电膜2限定、另外一边与所述透明导电膜2的外边界重合。
在本发明中,所述透明导电膜2能够实现电加热以除霜除雾、日光控制(防晒或遮阳)和/或低辐射等用途,具体包括至少一个金属层和/或金属合金层,所述金属层可以选用金(Au)、银(Ag)、铜(Cu)、铝(Al)或钼(Mo),所述金属合金层可以选用银合金,例如银金合金、银铟合金、银铜合金等;优选地,所述透明导电膜2包括至少一个银层和/或银合金层,每个银层或银合金层位于至少两个介质层之间,所述介质层的材料选自锌(Zn)、镁(Mg)、锡(Sn)、钛(Ti)、铌(Nb)、锆(Zr)、镍(Ni)、铟(In)、硅(Si)、铝(Al)、铈(Ce)、钨(W)、钼(Mo)、锑(Sb)、铋(Bi)等元素的氧化物中的至少一种,和/或选自硅(Si)、铝(Al)、锆(Zr)、钇(Y)、铈(Ce)、镧(La)等元素的氮化物、氮氧化物及其混合物中的至少一种。所述透明导电膜2可以通过化学气相沉积(CVD)或物理气相沉积(CVD)的方法直接沉积到平直玻璃板的表面上,例如通过磁控溅射沉积到浮法平板玻璃的表面上,沉积有透明导电膜2的平直玻璃板被加热软化后经过弯曲成型得到本发明所述的镀膜玻璃100;所述加热软化的温度大于或等于560℃,例如600℃以上,所述弯曲成型为汽车玻璃的重力弯曲成型工艺或压制弯曲成型工艺,所述透明导电膜2在加热软化的高温过程中,其自身的致密度会发生变化,使得所述透明导电膜2的方阻变小,即所述弯曲玻璃板1上的透明导电膜2的方阻比所述平直玻璃板上的透明导电膜的方阻小0~32%,更优选小10%~30%,例如所述透明导电膜2沉积平直玻璃板的表面上后的方阻为1.0Ω/口,经过加热软化和弯曲成型后,所述弯曲玻璃板1上的透明导电膜2的方阻为0.8Ω/口。
在图1中,所述透明导电膜2覆盖所述弯曲玻璃板1的大部分区域,为了保护所述透明导电膜2的四周边部不被腐蚀,优选所述透明导电膜2的四周边部比所述弯曲玻璃板1的四周边部向内缩进一端距离,例如1.5mm~20mm。
为了保证通信数据、图像数据和传感器数据等无障碍地穿过所述除膜区域101,所述除膜区域101内没有覆盖透明导电膜,即利用激光除膜技术使所述除膜区域101内的透明导电膜被全部去除,优选所述金属层和/或金属合金层的金属粒子在所述除膜区域101内的数量等于0,从而保证所述除膜区域101不对数据传输产生任何削弱影响;并且不破坏所述弯曲玻璃板1的表面,优选所述弯曲玻璃板1的可见光透过率减去所述除膜区域101的可见光透过率小于或等于5%,更优选小于或等于3%,最优选小于或等于1%甚至等于0,例如所述弯曲玻璃板1的可见光透过率为88.4%,所述除膜区域101的可见光透过率为85.9%;同时优选所述除膜区域101的雾度减去所述弯曲玻璃板1的雾度小于或等于2%,更优选小于或等于0.85%,最优选小于或等于0.4%甚至等于0,例如所述弯曲玻璃板1的雾度为0.07%,所述除膜区域101的雾度为1.15%;进一步改善了反射变形、天线信号透过和相机光谱特性。所述雾度是指由于光的散射而造成的损失,通常是指光的散射部分(散射分数或Td)与直接透过窗玻璃的光(TL)的比率,以百分比表示。
如图3和图4所示,在沉积有所述透明导电膜2的所述弯曲玻璃板1的表面上还设置有深色油墨层3,主要用于遮蔽车内的部件,能够保证镀膜玻璃100的周边颜色协调一致,提高整体外观和阻隔太阳辐射,避免车内部件老化,提高产品的稳定性和使用寿命;所述透明导电膜2至少部分地覆盖所述深色油墨层3,至少一个除膜区域101的至少部分位于所述深色油墨层3上的透明导电膜中,利用激光除膜技术使所述深色油墨层3上的除膜区域101内的透明导电膜被全部去除,优选所述金属层和/或金属合金层的金属粒子在所述深色油墨层3内的数量等于0,从而保证所述除膜区域101不对数据传输产生任何削弱影响;所述深色油墨层3通常环绕所述弯曲玻璃板1的四周边部,形成大致呈环状的不透明遮蔽区。当所述弯曲玻璃板1用作构成前挡风玻璃时,在所述弯曲玻璃板1的对应摄像机、激光雷达、雨感器等ADAS电子设备的区域即T形区也设置有深色油墨层3;所述T形区的深色油墨层3可以形成不透明遮蔽区,也可以形成点状油墨分散区,还可以一部分形成不透明遮蔽区、其他部分形成点状油墨分散区;在点状油墨分散区中,透明导电膜2部分地覆盖在深色油墨层3上,部分地覆盖在弯曲玻璃板1的表面上,至少一个除膜区域101位于所述点状油墨分散区中。
优选地,所述深色油墨层3的可见光透过率小于或等于1.5%,紫外线透过率小于或等于0.05%,所述深色油墨层3的材料可以选用陶瓷油墨或紫外线干燥油墨(也叫UV油墨);所述陶瓷油墨可以通过平面印刷等方式形成在平直玻璃板的表面上,然后同平直玻璃板一起经过至少560℃的高温热处理和弯曲成型,最终在弯曲玻璃板的表面上烧结成型以得到所述深色油墨层3;所述紫外线干燥油墨可以通过曲面印刷等方式形成在经过至少560℃的高温热处理和弯曲成型的弯曲玻璃板的表面上,然后在弯曲玻璃板的表面上通过小于或等于200℃的紫外线使其干燥固定以得到所述深色油墨层3。为了使所述深色油墨层3更加美观且更容易搭配,优选所述深色油墨层3的颜色为黑色或褐色等。
所述镀膜玻璃100可以单片使用,可以与形成夹层玻璃使用,本发明还提供一种包括该镀膜玻璃的夹层玻璃,如图5所示,所述夹层玻璃包括所述镀膜玻璃100、中间粘结层4和第二玻璃板5,所述中间粘结层4将所述镀膜玻璃100和所述第二玻璃板5粘接在一起。
其中,所述镀膜玻璃100作为外玻璃板时,所述透明导电膜2与所述中间粘结层4直接接触,即所述透明导电膜2位于所述夹层玻璃的第二表面;所述镀膜玻璃100作为内玻璃板时,优选所述透明导电膜2与所述中间粘结层4直接接触,即所述透明导电膜2位于所述夹层玻璃的第三表面;所述镀膜玻璃100作为内玻璃板时,所述透明导电膜2也可以与所述中间粘结层4远离,即所述透明导电膜2位于所述夹层玻璃的第四表面;通常,所述夹层玻璃的第一表面与车辆外部的空气接触,所述夹层玻璃的第四表面与车辆内部的空气接触。
在图5中,所述夹层玻璃还包括与所述透明导电膜2直接电接触的第一汇流母线6和第二汇流母线7,供电电源(未示出)可以通过所述第一汇流母线6和第二汇流母线7向所述透明导电膜2内输入电流,所述透明导电膜2在电流的作用下发热并产生热量,从而使所述夹层玻璃的温度升高以实现除霜除雾等功能。所述供电电源能够提供12~60V的供电电压,以适应燃油汽车、电动汽车等的使用要求;通常,所述第一汇流母线6和第二汇流母线7沿着夹层玻璃的两对两边设置且大致相互平行,以在它们之间形成均匀的电加热区域。所述第一汇流母线6和所述第二汇流母线7优选为导电银浆,可以通过丝网印刷等方式直接印刷到所述透明导电膜2上;当然,所述第一汇流母线6和所述第一汇流母线7也可以选用金属箔,所述金属箔具体可以为金箔、银箔、铜箔或铝箔等;所述第一汇流母线6和所述第二汇流母线7还可以同时选用导电银浆和金属箔,先将导电银浆直接印刷在所述透明导电膜2上,然后将金属箔通过粘贴等方式固定在所述导电银浆上,优选所述导电银浆的宽度大于或等于所述金属箔的宽度。
所述中间粘结层4用于将所述镀膜玻璃100和第二玻璃板5粘接固定在一起,例如可以选用聚碳酸酯(PC)、聚氯乙烯(PVC)、聚乙烯醇缩丁醛(PVB)、乙烯乙酸乙烯酯(EVA)、聚丙烯酸酯(PA)、聚甲基丙烯酸甲酯(PMMA)或聚氨酯(PUR)等。当然,所述中间粘结层4还可以具有其他功能,例如设置至少一个着色区用作阴影带从而降低太阳光对人眼的干扰或者增添红外线吸收剂从而具有防晒或隔热功能,又例如所述中间粘结层4还可以包含至少两层,其中一层的增塑剂含量更高从而具有隔音功能,或者其中一层具有楔形形状从而具有抬头显示(HUD)功能等。
在本发明中,所述第二玻璃板5优选为由平直玻璃板经过至少560℃的高温热处理和弯曲成型形成的弯曲玻璃板,或为厚度小于或等于1.1mm的化学钢化平直玻璃板,或为厚度小于或等于1.1mm的本体强化平直玻璃板;所述化学钢化平直玻璃板或所述本体强化平直玻璃板的厚度小于所述镀膜玻璃100的厚度至少0.7mm。同时,在所述第二玻璃板5的至少一个表面上也设置有深色油墨层,以在车内侧形成遮蔽区和保护车内的零部件,并且还能够用于提升局部的粘接性。
为了获得所述夹层玻璃,本发明还提供一种夹层玻璃的制造方法,所述夹层玻璃包括透明导电膜2,在所述透明导电膜2中设置有至少一个除膜区域101,其特征在于,包括以下步骤:
步骤1:准备平直玻璃板,在所述平直玻璃板上设置至少一个除膜保护层8;
根据夹层玻璃中的每个除膜区域101的位置,在平直玻璃板的表面上的对应区域设置所述除膜保护层8,每个除膜保护层8与每个除膜区域101的位置一一对应,所述除膜保护层8用于在利用激光除膜技术使每个除膜区域101内的透明导电膜2被彻底去除时保护玻璃表面或深色油墨表面;当至少一个除膜区域101的至少部分位于所述深色油墨层3上时,至少一个所述除膜保护层8的至少部分对应地位于所述深色油墨层3上;所述除膜保护层8由用于激光除膜的印刷组合物印刷到平直玻璃板的表面或所述深色油墨层的表面上并固化后形成,所述固化的温度小于或等于200℃,所述印刷组合物按质量百分比计包括60%~70%无机隔离颗粒、7%~15%树脂添加剂、15%~22%颜料和5%~10%有机溶剂。
所述无机隔离颗粒具有良好的热传导性和耐热性,用于保护玻璃表面或深色油墨表面不被激光破坏,优选所述无机隔离颗粒的粒径小于或等于2微米,所述无机隔离颗粒包括硅藻土、晶体硅、石英砂中的至少一种;所述树脂添加剂用于调整固化效率和提升所述无机隔离颗粒与玻璃表面或深色油墨表面之间的结合力,并且能够在经过至少560℃的高温热处理过程中碳化,使所述除膜保护层8与玻璃表面或深色油墨表面之间的结合断裂,保证所述除膜保护层8能够在激光除膜后被快速清除干净,所述树脂添加剂优选包括丙烯酸酯;所述颜料用于稳定热传导性能,并且起到遮蔽和提供色泽的作用,优选所述颜料包括铁(Fe)、铜(Cu)、钴(Co)、镍(Ni)、锰(Mn)等金属的氧化物中的至少一种;所述有机溶剂用于调整所述印刷组合物的粘度和流动性,优选所述有机溶剂包括二苯基甲酮(C13H10O)和异丙基噻吨酮(C16H14OS)中的至少一种。
优选地,在所述平直玻璃板的设置有除膜保护层8的表面上还设置深色油墨层3,所述深色油墨层3可以通过平面印刷等方式形成在所述平直玻璃板的表面上,所述深色油墨层3可以在所述除膜保护层8之前形成在所述平直玻璃板的同一表面上,也可以在所述除膜保护层8之后形成在所述平直玻璃板的同一表面上,甚至与所述除膜保护层8同时形成在所述平直玻璃板的同一表面上;当至少一个除膜区域101的至少部分位于所述深色油墨层3上时,所述深色油墨层3在所述除膜保护层8之前形成在所述平直玻璃板的同一表面上,然后将至少一个所述除膜保护层8的至少部分对应地设置在所述深色油墨层3上。本发明以所述深色油墨层3在所述除膜保护层8之前形成在所述平直玻璃板的同一表面上举例,通过平面印刷方式将所述深色油墨层3印刷在所述平直玻璃板的表面上,并对所述深色油墨层3进行预烧结固化,然后通过丝网印刷工艺,将所述除膜保护层8印刷到所述平直玻璃板的同一表面上对应所述除膜区域101的区域,并对所述除膜保护层8进行烘干固化;其中,优选所述深色油墨层3的厚度为15~40微米,所述除膜保护层8的厚度为5~20微米,所述深色油墨层3的厚度大于或等于所述除膜保护层8的厚度。
步骤2:在所述平直玻璃板的设置有除膜保护层8的表面上沉积透明导电膜2,所述透明导电膜2至少部分地覆盖所述除膜保护层8;
当所述平直玻璃板的设置有除膜保护层8的表面上还设置有深色油墨层3时,所述透明导电膜2至少部分地覆盖所述深色油墨层3;
所述透明导电膜2可以通过化学气相沉积(CVD)或物理气相沉积(CVD)的方法直接沉积到平直玻璃板的表面上,例如通过磁控溅射进行沉积;所述透明导电膜2如果还用于电加热以实现除霜除雾等功能,在所述透明导电膜2沉积到所述平直玻璃板的表面上之后,还在所述透明导电膜2的表面上印刷导电银浆以形成第一汇流母线6和第二汇流母线7,供电电源可以通过所述第一汇流母线6和第二汇流母线7向所述透明导电膜2内输入电流;
为了保护所述透明导电膜2的四周边部不被腐蚀,在所述透明导电膜2沉积到所述平直玻璃板的整个表面上之后,通过机械剥离、化学剥蚀和/或激光除膜等技术将四周边部的透明导电膜去除,去除的宽度为1.5mm~20mm。
步骤3:将带有透明导电膜2和除膜保护层8的平直玻璃板经过至少560℃的高温热处理和弯曲成型,获得弯曲玻璃板1;
如图6a所示,所述弯曲玻璃板1的表面上具有一起经过至少560℃的高温热处理和弯曲成型的透明导电膜2和除膜保护层8;如图7a所示,所述弯曲玻璃板1的表面上还具有一起经过至少560℃的高温热处理和弯曲成型的深色油墨层3;所述经过至少560℃的高温热处理和弯曲成型可以举例为汽车玻璃的烘弯或钢化等弯曲生产工艺。
在所述经过至少560℃的高温热处理的过程中,所述平直玻璃板被加热软化以进行弯曲成型;所述透明导电膜2自身的致密度会发生变化,使其方阻变小,即所述弯曲玻璃板1上的透明导电2的方阻小于所述平直玻璃板上的透明导电膜2的方阻;所述除膜保护层8中的树脂添加剂碳化,所述除膜保护层8与玻璃表面或深色油墨表面之间的结合断裂,使它们之间的结合力变小,即所述弯曲玻璃板1上的除膜保护层8与玻璃板表面或深色油墨层表面之间的结合力小于所述平直玻璃板上的除膜保护层8与玻璃板表面或深色油墨层表面之间的结合力。
当所述平直玻璃板上还设置有深色油墨层3时,所述深色油墨层3在所述经过至少560℃的高温热处理过程中被烧结固化,使它们之间的结合力变大,即所述弯曲玻璃板1上的深色油墨层3与玻璃板表面之间的结合力大于所述平直玻璃板上的深色油墨层3与玻璃板表面之间的结合力;当所述透明导电膜2上设置有导电银浆时,所述导电银浆在所述经过至少560℃的高温热处理过程中被激发活性,使所述导电银浆与所述透明导电膜2紧密结合,从而提升导电连接性能。
步骤4:利用激光器9产生的激光束91去除所述弯曲玻璃板1上的所述除膜保护层8上的透明导电膜2;
在图6a和图7a中,激光器9产生激光束91对覆盖在所述除膜保护层8上的透明导电膜2进行除膜,使所述除膜保护层8上的透明导电膜2被全部去除,由于所述除膜保护层8对激光束91的阻隔,从而避免激光束91直接照射玻璃板表面或深色油墨层表面,起到保护所述弯曲玻璃板1和所述深色油墨层3的作用;所述激光器91优选为红外线激光器或绿光激光器,所述红外线激光器用于产生波长为1053nm或1064nm的激光束91,所述绿光激光器用于产生波长为527nm或532nm的激光束91。为了使所述除膜保护层8上的透明导电膜2被全部去除,可以使所述除膜保护层8的至少部分被所述激光束91破坏。
如图6b和图7b所述,所述除膜保护层8的表面上的透明导电膜2被全部去除,所述除膜保护层8在所述弯曲玻璃板1上或在所述深色油墨层3上形成裸露,便于后续被清除干净。
步骤5:清除所述弯曲玻璃板1上的所述除膜保护层8,在所述透明导电膜2中形成至少一个除膜区域101,获得镀膜玻璃100;
将图6b和图7b中的所述弯曲玻璃板1上的所述除膜保护层8清除,可以通过清洗或机械摩擦将所述除膜保护层8清除,例如直接采用高压水冲洗,获得如图6c或7c的镀膜玻璃100,图6c示出了所述弯曲玻璃板1的表面上形成除膜区域101,图7c示出了所述深色油墨层3的表面上形成除膜区域101;所述镀膜玻璃100的型面质量好、光畸变小;
步骤6:准备第二玻璃板5和至少一片中间粘结层4,将所述镀膜玻璃100和所述第二玻璃板5通过所述至少一片中间粘结层4进行合片,获得夹层玻璃;
其中,所述第二玻璃板5为由平直玻璃板经过至少560℃的高温热处理和弯曲成型形成的弯曲玻璃板,或为厚度小于或等于1.1mm的化学钢化平直玻璃板,或为厚度小于或等于1.1mm的本体强化平直玻璃板;所述化学钢化平直玻璃板主要是通过不同离子半径的离子在薄玻璃或超薄玻璃表面进行离子交换,使薄玻璃或超薄玻璃表面产生较高的表面应力,并伴随一定的应力层深度,从而提高薄玻璃或超薄玻璃在力学性能方面的强度,所述化学钢化平直玻璃板优选为碱性铝硅酸盐玻璃;所述本体强化平直玻璃板是指既不需要经过物理钢化、也不需要经过化学钢化的原片玻璃板,该原片玻璃板可直接与所述镀膜玻璃100进行合片形成夹层玻璃,符合车辆上的夹层玻璃的使用标准,例如中国的《GB9656-2016汽车安全玻璃》等,所述本体强化平直玻璃板优选为硼硅酸盐玻璃;
所述镀膜玻璃100的厚度比所述化学钢化平直玻璃板的厚度或所述本体强化平直玻璃板的厚度大至少0.7mm,所述化学钢化平直玻璃板和所述本体强化平直玻璃板均可以通过冷成型工艺实现与所述镀膜玻璃100的粘合并最终弯曲成型。优选地,所述镀膜玻璃100作为夹层玻璃的外玻璃板,所述透明导电膜2与所述中间粘结层4直接接触,所述第二玻璃板5作为夹层玻璃的内玻璃板。
以上内容对本发明所述的一种镀膜玻璃及其夹层玻璃以及一种用于激光除膜的印刷组合物和夹层玻璃的制造方法进行了具体描述,但是本发明不受以上描述的具体实施方式内容的局限,所以凡依据本发明的技术要点进行的任何改进、等同修改和替换等,均属于本发明保护的范围。

Claims (16)

1.一种镀膜玻璃,包括弯曲玻璃板和透明导电膜,所述透明导电膜沉积在所述弯曲玻璃板的至少一个表面上,在所述透明导电膜中设置有至少一个除膜区域,所述除膜区域内没有覆盖透明导电膜,其特征在于:所述透明导电膜包括至少一个金属层和/或金属合金层,所述弯曲玻璃板和所述透明导电膜通过将沉积有透明导电膜的平直玻璃板经过至少560℃的高温热处理和弯曲成型获得,所述弯曲玻璃板的可见光透过率减去所述除膜区域的可见光透过率小于或等于5%,所述除膜区域的雾度减去所述弯曲玻璃板的雾度小于或等于2%。
2.根据权利要求1所述的镀膜玻璃,其特征在于:所述金属层选用金、银、铜、铝或钼,所述金属合金层为银合金。
3.根据权利要求1所述的镀膜玻璃,其特征在于:所述金属层和/或金属合金层的金属粒子在所述除膜区域内的数量等于0。
4.根据权利要求1所述的镀膜玻璃,其特征在于:所述透明导电膜包括至少一个银层和/或银合金层,每个银层或银合金层位于至少两个介质层之间,所述介质层的材料选自锌、镁、锡、钛、铌、锆、镍、铟、硅、铝、铈、钨、钼、锑、铋元素的氧化物中的至少一种,和/或选自硅、铝、锆、钇、铈、镧元素的氮化物、氮氧化物及其混合物中的至少一种。
5.根据权利要求1所述的镀膜玻璃,其特征在于:所述弯曲玻璃板上的透明导电膜的方阻比所述平直玻璃板上的透明导电膜的方阻小0~32%。
6.根据权利要求1所述的镀膜玻璃,其特征在于:所述弯曲玻璃板的可见光透过率减去所述除膜区域的可见光透过率小于或等于1%,所述除膜区域的雾度减去所述弯曲玻璃板的雾度小于或等于0.4%。
7.根据权利要求1所述的镀膜玻璃,其特征在于:所述弯曲玻璃板的可见光透过率减去所述除膜区域的可见光透过率等于0,所述除膜区域的雾度减去所述弯曲玻璃板的雾度等于0。
8.根据权利要求1所述的镀膜玻璃,其特征在于:在沉积有所述透明导电膜的所述弯曲玻璃板的表面上还设置有深色油墨层,所述透明导电膜至少部分地覆盖所述深色油墨层,至少一个除膜区域的至少部分位于所述深色油墨层上的透明导电膜中。
9.根据权利要求8所述的镀膜玻璃,其特征在于:所述金属层和/或金属合金层的金属粒子在所述深色油墨层内的数量等于0。
10.根据权利要求8所述的镀膜玻璃,其特征在于:所述深色油墨层的可见光透过率小于或等于1.5%,紫外线透过率小于或等于0.05%,所述深色油墨层的材料选用陶瓷油墨或紫外线干燥油墨。
11.一种夹层玻璃,其特征在于:包括根据权利要求1~10任意一项所述的镀膜玻璃、中间粘结层和第二玻璃板,所述中间粘结层将所述镀膜玻璃和所述第二玻璃板粘接在一起。
12.根据权利要求10所述的夹层玻璃,其特征在于:所述透明导电膜与所述中间粘结层直接接触。
13.根据权利要求10所述的夹层玻璃,其特征在于:所述夹层玻璃还包括与所述透明导电膜直接电接触的第一汇流母线和第二汇流母线,供电电源通过所述第一汇流母线和第二汇流母线向所述透明导电膜内输入电流,所述供电电源能够提供12~60V的供电电压。
14.根据权利要求10所述的夹层玻璃,其特征在于:所述第一汇流母线和所述第二汇流母线为导电银浆和/或金属箔,所述金属箔为金箔、银箔、铜箔或铝箔。
15.根据权利要求10所述的夹层玻璃,其特征在于:所述第二玻璃板为由平直玻璃板经过至少560℃的高温热处理和弯曲成型形成,或为厚度小于或等于1.1mm的化学钢化玻璃板,或为厚度小于或等于1.1mm的本体强化平直玻璃板。
16.根据权利要求10所述的夹层玻璃,其特征在于:所述镀膜玻璃上设置有深色油墨层,所述深色油墨层的至少部分形成点状油墨分散区,所述点状油墨分散区中的透明导电膜部分地覆盖在深色油墨层上、部分地覆盖在弯曲玻璃板的表面上,至少一个除膜区域位于所述点状油墨分散区中。
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