CN113453882B - 具有集成可成形模具的热成形挡风玻璃堆叠 - Google Patents

具有集成可成形模具的热成形挡风玻璃堆叠 Download PDF

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CN113453882B
CN113453882B CN202080011993.6A CN202080011993A CN113453882B CN 113453882 B CN113453882 B CN 113453882B CN 202080011993 A CN202080011993 A CN 202080011993A CN 113453882 B CN113453882 B CN 113453882B
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stack
lenses
lens
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斯蒂芬·S·威尔逊
巴特·E·威尔逊
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Ruisiling Optics Co ltd
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Abstract

一种在弯曲基底上安装两个或更多透镜的堆叠的方法，包括：将可塑覆盖物置于弯曲基底上，可塑覆盖物包括具有两个或更多透镜的堆叠、介于两个或更多透镜中每对相邻透镜之间的粘合剂层、以及设置在堆叠的最外透镜上的5个牺牲层，该牺牲层包括牺牲透镜和介于牺牲透镜与堆叠的最外透镜之间的牺牲粘合剂。该方法可以包括向牺牲层施加热量和压力，以及剥离牺牲层以露出两个或更多透镜的堆叠。

Description

具有集成可成形模具的热成形挡风玻璃堆叠
相关申请的交叉引用
本申请涉及并要求2019年2月1日提交的名称为“具有集成可成形模具的热成形挡风玻璃堆叠(Thermoform Windshield Stack With Integrated Formable Mold)”的美国临时申请No.62/799,880的优先权，该申请的全部内容通过引用明确地并入本文。
声明：联邦政府赞助的研究/开发
不适用
技术领域
本公开总体上涉及窗用透明覆盖物，并且更具体地涉及具有多个透镜的透明覆盖物，所述多个透镜一个接一个地堆叠并通过粘合剂粘合在一起。
背景技术
将透明透镜固定到如挡风玻璃(也称为风挡)等的弯曲基底上可具有多种益处。这种覆盖物可以提供以下防护：防止点蚀和裂纹、着色(例如，为了隐私)、热绝缘、阻挡紫外线(UV)辐射、和/或装饰。当最外透镜变脏并且妨碍驾驶员的视野时(例如可能发生在越野用车辆中)，这种透明透镜的堆叠可以被容易地撕掉。
虽然典型的挡风玻璃的表面通常表现出多向曲率，但是(例如以卷对卷工艺制造的聚对苯二甲酸乙二醇酯(PET)膜的情况下)，透明透镜本身可以是平坦的。为了将平坦膜安装到复合曲线挡风玻璃表面，例如，通过将膜铺设在挡风玻璃上并对最上表面施加热量使膜收缩或拉伸从而呈现挡风玻璃的形状，由此使得膜可以在挡风玻璃上覆盖成形。然而，该过程可能导致加热不均匀或过热，这可能引起膜的光学畸变并且可能产生膜与挡风玻璃粘合不充分的区域。此外，安装者尝试用卡片或刮刀向膜施加压力，这可能导致安装过程中永久性地划伤可见表面。
发明内容
本公开考虑了用于克服上述相关技术的缺点的各种系统和方法。本公开实施方案的一个方面是在弯曲基底上安装两个或更多透镜的堆叠的方法。该方法可以包括将可塑覆盖物置于弯曲基底上，可塑覆盖物包括具有两个或更多透镜的堆叠、介于两个或更多透镜中每对相邻透镜之间的粘合剂层、以及设置在堆叠的最外透镜上的牺牲层，该牺牲层包括牺牲透镜和介于牺牲透镜与堆叠的最外透镜之间的牺牲粘合剂。该方法可以包括向牺牲层施加热量和压力，以及剥离牺牲层以露出具有两个或更多透镜的堆叠。
弯曲基底可为复合弯曲基底。弯曲基底可为挡风玻璃。
牺牲层可以比堆叠的最外透镜更耐热。
牺牲层可以比堆叠的最外透镜更不耐划伤。
牺牲透镜可以包括双轴取向的聚对苯二甲酸乙二醇酯膜。双轴取向的聚对苯二甲酸乙二醇酯膜可以耐受室温至220℃的温度两小时。
牺牲透镜可以包括不透明聚酯膜。堆叠的最外透镜可以包括透明聚对苯二甲酸乙二醇酯膜。
本公开实施方案的另一方面是可固定于弯曲基底的可塑覆盖物，该可塑覆盖物可包括具有两个或更多透镜的堆叠、介于两个或更多透镜中每对相邻透镜之间的粘合剂层、以及设置在堆叠的最外透镜上的牺牲层，该牺牲层包括牺牲透镜和介于牺牲透镜与堆叠的最外透镜之间的牺牲粘合剂，该牺牲层比堆叠的最外透镜更耐热。
牺牲透镜可以包括双轴取向的聚对苯二甲酸乙二醇酯膜。双轴取向的聚对苯二甲酸乙二醇酯膜可以耐受室温至220℃的温度两小时。
牺牲透镜可以包括不透明聚酯膜。堆叠的最外透镜可以包括透明聚对苯二甲酸乙二醇酯膜。
本公开的实施方案的又一方面是可固定于弯曲基底的可塑覆盖物。可塑覆盖物可以包括具有两个或更多透镜的堆叠、介于两个或更多透镜中每对相邻透镜之间的粘合剂层、以及设置在堆叠的最外透镜上的牺牲层，该牺牲层包括牺牲透镜和介于牺牲透镜与堆叠的最外透镜之间的牺牲粘合剂，该牺牲层比堆叠的最外透镜更不耐划伤。
牺牲透镜可以包括双轴取向的聚对苯二甲酸乙二醇酯膜。双轴取向的聚对苯二甲酸乙二醇酯膜可以耐受室温至220℃的温度两小时。
牺牲透镜可以包括不透明聚酯膜。堆叠的最外透镜可以包括透明聚对苯二甲酸乙二醇酯膜。
附图说明
通过参考以下描述和附图，将更好地理解本文公开的各实施方案的以上及其他特征和优点，其中相同的附图标记始终表示相同的部件，并且：
图1为根据本公开实施方案的可塑覆盖物的示意性侧视图；
图2示出在向可塑覆盖物的牺牲层施加热量和压力的过程开始时置于挡风玻璃上的可塑覆盖物；
图3示出在施加热量和压力的过程结束时挡风玻璃上的可塑覆盖物；
图4示出了剥落牺牲层以露出透明透镜的堆叠时挡风玻璃上的可塑覆盖物；
图5示出经修整以适合挡风玻璃之后的透明透镜的堆叠；以及
图6示出根据本公开实施方案的示例性操作流程。
具体实施方式
本公开包括具有两个或更多透镜的堆叠的可塑覆盖物及其安装方法的各种实施方案。下面结合附图所进行的详细描述旨在作为对若干当前预期的实施方案的描述，而不是旨在表示可以开发或利用所公开发明的唯一形式。本说明书结合所记载的实施方案阐述了其功能和特征。然而，应当理解的是，相同或者等效的功能可以通过同样涵盖在本公开的范围内的其他实施方案实现。还应当理解的是，如第一和第二等关系术语仅用于将一个实体与另一个实体区分开，而不必按这些实体之间的顺序要求或者暗示任何实际的这种关系。
图1为根据本公开实施方案的可塑覆盖物100的示意性侧视图。作为安装具有透镜110a、110b、...110n(统称为透镜110)的堆叠的过程的一部分，可以将可塑覆盖物100固定于诸如挡风玻璃之类的弯曲基底10。安装的透镜110堆叠可为基底10提供保护、着色、热绝缘、阻挡紫外线(UV)辐射、装饰，和/或在制品的寿命期间根据需要剥离并丢弃最外层110n(且此后新露出任意层110)的能力。除了透镜110之外，可塑覆盖物100可以包括分别设置在各个透镜110上的粘合剂层120a、120b、...120n(统称为粘合剂层120)，使得粘合剂层120介于堆叠的每对相邻透镜110之间。在透镜110堆叠的最外透镜110n上，可提供牺牲层130，从而实现改进的将透镜110堆叠安装到基底10的工艺。牺牲层130可包括牺牲透镜132和介于牺牲透镜132与透镜110堆叠的最外透镜110n之间的牺牲粘合剂134。当安装透镜110堆叠时，可向牺牲层130施加热量和压力以使透镜110堆叠适合弯曲基底10的形状。此后，可剥离牺牲层130以露出包括已安装透镜110的最终制品140。
当在没有牺牲层130的情况下，使透镜110堆叠在弯曲基底10上覆盖成形时，该过程可能会导致如上所述的加热不均匀或过热，并且可能用卡片或刮刀永久性地划伤最外透镜110n。发明人已经发现，这些问题主要源于当透镜110堆叠与由弯曲基底10表示的凸表面相符时缺少凹模腔施加压力。作为结果，当安装者试图将透镜110堆叠模制到弯曲基底10时，热量和压力两者中的任一者都不能均匀地分布，从而导致所述问题。通过提供牺牲层130作为缺失的凹模腔，所公开的可塑覆盖物100可以以至少两种方式克服这些缺陷。首先，牺牲层130可以使得安装者施加热量和压力而不用担心划伤或以其他方式损坏最终制品。可以仅将牺牲层130连带任何表面损坏一起丢弃，而位于其下的透镜110堆叠的最外透镜110n保持无瑕疵。第二，当热量和压力通过介于其间的牺牲层130施加到透镜110堆叠时，牺牲层130可用于在更大区域上分布热量及压力，从而使得当牺牲层130和位于其下的透镜110堆叠一起适形于弯曲基底10的形状时，能够更均匀地施加热量和压力。
透镜110可包括透明聚对苯二甲酸乙二醇酯(PET)膜，例如双轴取向的聚对苯二甲酸乙二醇酯(BoPET)，并且可由DuPont公司以注册商标Mylar出售的聚酯膜片材制成。各透镜110的厚度可以在0.5密耳和7密耳(1密耳为0.001")之间，例如2密耳。即使在粘合剂层120的粘合剂材料施加到2密耳厚的透镜110之后，由于粘合剂层120仅具有公称厚度，因此2密耳厚的透镜110和粘合剂层120的组合厚度仍可为2密耳。
如2003年3月25日公告的名称为“Tear-off Optical Stack Having PeripheralSeal Mount”的Wilson的美国专利No.6,536,045所述，用于粘合剂层120的粘合剂可施加在(例如)可塑覆盖物100的周边附近的选定区域，该专利的全部内容通过引用明确地并入本文。粘合剂层120可由光学透明的低粘性材料制成，并且可包括水基丙烯酸光学透明粘合剂或油基透明粘合剂。用于将可塑覆盖物100固定于基底10的粘合剂层120a可以与介于堆叠的每对相邻透镜110之间的粘合剂层120b、...120n等粘合剂层相同或不同(例如，更强)。例如，在使用期间，在不从基底10上移除整个透镜110堆叠而撕掉单个透镜110的情况下，可以使用更强的粘合剂。沿着相同的思路，用于介于每对相邻透镜110之间的粘合剂层120b、...120n的粘合剂可以比用于牺牲层130的牺牲粘合剂134更强，使得可以在不从透镜110堆叠中移除最外透镜110n的情况下，撕掉牺牲层130。牺牲粘合剂134可类似地为低粘性材料，并且可包括水基丙烯酸光学透明粘合剂或油基透明粘合剂。然而，对于具有牺牲粘合剂134的情况，由于在最终制品140中去除牺牲粘合剂134，因此也可以用不透明粘合剂替代。
可以优化透镜110的耐划伤性和/或阻挡(吸收或反射)UV辐射。例如，各透镜110的外侧可以由沉积、喷涂、层叠或其他方式涂覆涂层(例如，硅酯丙烯酸酯低聚物和/或丙烯酸酯化聚氨酯多元醇)，如所期望的适于最终制品140的特性，该涂层优化耐划伤性和/或阻挡UV辐射性能。由于在安装完成之后将不存在牺牲层130，在牺牲层130的制作中这些性质可以放宽。因此，例如，牺牲层130可以比透镜120堆叠的最外透镜120n更不耐划伤。同时，可优化牺牲层130的耐热性，例如，涂覆具有更优耐热性的涂层(例如，硅酯丙烯酸酯低聚物和/或丙烯酸酯化聚氨酯多元醇)，因为这样可直接加热牺牲层130，作为使可塑覆盖物100热成形为弯曲基底10的形状的一部分。这种耐热性可在位于其下的透镜100堆叠中得以放宽，因为这些透镜可仅通过牺牲层130间接地受热。因此，例如，牺牲层130可比透镜100堆叠的最外透镜110n更耐热。
牺牲层130可由高温PET制成，例如，可耐受室温至220℃的温度两小时(例如，不会劣化)的PET。高温PET可为透明BoPET，能够在模制过程中观察位于其下的透镜110堆叠，并且可为(例如)由Mitsubishi Polyester Film Group以商品名Hostaphan RBB出售的聚酯膜。当在模制过程中使用热空气加热牺牲层130时，可优选这种高温BoPET。或者，牺牲层130可由不透明(例如，白色)聚酯膜制成，例如由Mitsubishi Polyester Film Group以商品名Hostaphan WIN出售的聚酯膜。当在模制过程中使用红外加热器加热牺牲层130时，这种不透明聚酯膜可提供增加的热均匀性。
虽然可以优化牺牲层130(例如，牺牲透镜132和/或牺牲粘合剂134)以承受安装过程的热量并且将热量和压力均匀地分布至位于其下的透镜110堆叠，但是牺牲层130通常不必满足位于其下的透镜110堆叠的更严格的性能标准。例如，可以将透镜堆叠设计为满足(例如)在美国国家标准协会(ANSI)标准Z26.1-1966和Z26.la-1969中阐述的可见光透射的联邦标准(例如70％)、以及如上所述的耐划伤性(例如，通过挡风玻璃刮水器)和/或吸收或反射UV光，以保护透镜110不受阳光损害。通过放宽对牺牲层130的这些要求，同时提供更坚固的表面以用于在安装期间无顾虑地施加热量和压力，可塑覆盖物100使得能够以更有效的方法安装透镜110堆叠。以牺牲层130作为凹模腔，使具有透镜110和粘合剂120的各层更好地与弯曲基底10保持、成形和固化，并且在安装过程期间不会划伤。
图2示出在向可塑覆盖物100的牺牲层130施加热量和压力的过程开始时置于汽车挡风玻璃20上的可塑覆盖物100，挡风玻璃作为基底10。如2016年3月29日公告的名称为“Adhesive Mountable Stack of Removable Layers”的Wilson的美国专利No.9,295,297所述，可塑覆盖物100可通过干涂粘合剂120a粘合至挡风玻璃(参见图1)，该专利的全部内容通过引用明确地并入本文。或者，如2015年9月8日公告的名称为“Touch Screen Shield”的Wilson的美国专利No.9,128,545所述，可以使用湿涂粘合剂120a，该专利的全部内容通过引用明确地并入本文。由于可塑覆盖物100可以是平坦的(例如，由卷对卷工艺制造)，因此可塑覆盖物100最初可不适形于挡风玻璃的弯曲形状，从而在可塑覆盖物100与挡风玻璃之间形成或大或小的粘合区域和气穴/气泡。因此，为了使可塑覆盖物100适形于挡风玻璃的形状，可使用如热空气源(例如，热风枪或吹风干燥器)或红外加热器等的加热器30施加热量和压力。同时，可以使用卡片或刮刀对可塑覆盖物100施加压力。当安装者加热并向下按压可塑覆盖物100的牺牲层130时，牺牲层130可收缩并拉伸以呈现与弯曲基底10(挡风玻璃)相对应的轮廓，其中透镜110堆叠位于牺牲层和弯曲基底之间。这样，牺牲层130可以用作凹模腔将位于其下的透镜110堆叠热成形为挡风玻璃的形状，均匀地分布热量和压力以将透镜110收缩和拉伸为正确的形状并固化粘合剂层120。
图3示出在施加热量和压力的过程结束时挡风玻璃上的可塑覆盖物100。在该阶段，将包括牺牲层130以及位于其下的透镜110的可塑覆盖物100模制成挡风玻璃的弯曲形状，而没有气穴/气泡。牺牲层130的上表面可能具有因安装者使用刮刀或卡片向可塑覆盖物100施加压力时引起的各种划痕和其他瑕疵。然而，由于位于其下的透镜110受到牺牲层130的保护，因此未接触。
图4示出当剥离牺牲层130以露出透明透镜110堆叠时挡风玻璃上的可塑覆盖物100。保留在挡风玻璃上的是包括透镜110堆叠和粘合剂层120的最终制品140(参见图1)。最终制品140可以满足如上所述的性能标准，包括可见光透射(例如，70％)以及耐划伤性和/或UV吸收或阻隔的联邦标准。最终制品140的透镜110可以精确地适形于挡风玻璃的形状，并且甚至在最外透镜110n上也可以没有瑕疵。可以仅丢弃剥离的牺牲层130。
图5示出在修整透明透镜110堆叠以适合作为基底10的挡风玻璃之后包括透明透镜110的堆叠的最终制品140。可以使用如具有不锈钢刀片(碳刀片可能损坏挡风玻璃)的美工刀或开箱刀等刀具修整透明透镜110堆叠。如图5所示，可以在已经从可塑覆盖物100去除牺牲层130之后进行修整，使得仅修整露出的最终制品140。或者，如图3所示，一旦可塑覆盖物100已经适形于挡风玻璃的形状，就可以在去除牺牲层130之前进行修整。在任一种情况下，经修整的最终制品140可以有效地不可见，因为经修整的最终制品140匹配下方的挡风玻璃的形状(尽管经修整的最终制品可以如在窗户着色的情况下改变挡风玻璃的颜色)。
图6示出根据本公开实施方案的示例性操作流程。图6的操作流程可作为安装包括图1所示的透镜110堆叠的最终制品140的示例性方法。首先，可将包括最终制品140和牺牲层130二者的可塑覆盖物100置于如图2所示的汽车20的挡风玻璃等的弯曲基底10上(步骤610)，其中粘合剂层120a在挡风玻璃上、牺牲层130背离挡风玻璃。为了更容易安装，可以粗切可塑覆盖物100(例如，使用电动薄膜切削器)以不延伸到挡风玻璃外太远的位置。操作流程可以继续，如结合图2和图3所描述的，将热量和压力施加到可塑覆盖物100的牺牲层130，以将可塑覆盖物100热成形为挡风玻璃的弯曲形状(步骤620)。在使可塑覆盖物100冷却之后，操作流程可结束于剥离牺牲层130以露出如结合图4所述的最终制品140(步骤630)以及进行如结合图5所述的最终修整(步骤640)。如上所述，可以以图6所示的顺序或相反的顺序进行步骤630和640。至此，包括透镜110堆叠的最终制品140被均匀地形成并固定在挡风玻璃表面。
图1的实例中示出三个透镜110。然而，可以预期的是，可塑覆盖物100可以包括具有四个或更多透镜110的堆叠、或具有两个透镜110的堆叠、或者甚至单个透镜110，透镜110的数量取决于具体应用。与常理相反，发明人已经发现，具有多个透镜110的堆叠比具有单个透镜110的堆叠更容易热成形至弯曲基底10。
在本公开的全文中，广泛使用的词语“透明”涵盖可以被透过其观察的任何材料。词语“透明”并不排除半透明、模糊、磨砂、有色或着色的材料。
可以按照如旋涂、浸涂、或真空沉积等已知的方法涂布本公开全文中所描述的涂层。
通过实例而非限制性的方式给出以上描述。根据上述公开，本领域技术人员可以设计出在此公开的本发明的范围和主旨内的变化。此外，本文公开的各实施方案的多个特征可单独使用，或者不同特征彼此组合使用，并且无意限制于本文所描述的具体组合。因此，权利要求的范围不受所示出的各实施方案的限制。

Claims (20)

1.一种在弯曲基底上安装具有两个或更多透镜的堆叠的方法，该方法包括：
将可塑覆盖物置于弯曲基底的凸表面上，所述可塑覆盖物包括具有两个或更多透镜的堆叠、介于所述两个或更多透镜中每对相邻透镜之间的粘合剂层、以及设置在所述堆叠的最外透镜上并且作为凹模腔的牺牲层，所述牺牲层包括牺牲透镜和介于所述牺牲透镜与所述堆叠的最外透镜之间的牺牲粘合剂；
向所述牺牲层施加热量和压力，使得所述牺牲层和所述两个或更多透镜的堆叠一起适形于所述弯曲基底的形状；以及
剥离所述牺牲层以露出所述具有两个或更多透镜的堆叠，
其中所述牺牲层比所述堆叠的最外透镜更耐热，使得所述牺牲层能够承受直接施加的热量而不造成劣化，所述直接施加的热量如果直接施加到所述堆叠的最外透镜的话，则会导致所述堆叠的最外透镜的劣化。
2.根据权利要求1所述的方法，其中所述弯曲基底为复合弯曲基底。
3.根据权利要求2所述的方法，其中所述弯曲基底为挡风玻璃。
4.根据权利要求1所述的方法，其中所述牺牲层比所述堆叠的最外透镜更耐热。
5.根据权利要求4所述的方法，其中所述牺牲层比所述堆叠的最外透镜更不耐划伤。
6.根据权利要求1所述的方法，其中所述牺牲层比所述堆叠的最外透镜更不耐划伤。
7.根据权利要求1所述的方法，其中所述牺牲透镜包括双轴取向的聚对苯二甲酸乙二醇酯膜。
8.根据权利要求7所述的方法，其中所述双轴取向的聚对苯二甲酸乙二醇酯膜能够耐受室温至220℃的温度两小时。
9.根据权利要求1所述的方法，其中所述牺牲透镜包括不透明聚酯膜。
10.根据权利要求9所述的方法，其中所述堆叠的最外透镜包括透明聚对苯二甲酸乙二醇酯膜。
11.一种固定于弯曲基底的凸表面上的可塑覆盖物，该可塑覆盖物包括：
具有两个或更多透镜的堆叠；
介于所述两个或更多透镜中每对相邻透镜之间的粘合剂层；
设置在所述堆叠的最外透镜上并且作为凹模腔的牺牲层，所述牺牲层包括牺牲透镜和介于所述牺牲透镜与所述堆叠的最外透镜之间的牺牲粘合剂，所述牺牲层比所述堆叠的最外透镜更耐热，使得所述牺牲层能够承受直接施加的热量而不造成劣化，所述直接施加的热量如果直接施加到所述堆叠的最外透镜的话，则会导致所述堆叠的最外透镜的劣化，其中所述牺牲层和所述两个或更多透镜的堆叠一起适形于所述弯曲基底的形状。
12.根据权利要求11所述的可塑覆盖物，其中所述牺牲透镜包括双轴取向的聚对苯二甲酸乙二醇酯膜。
13.根据权利要求12所述的可塑覆盖物，其中所述双轴取向的聚对苯二甲酸乙二醇酯膜能够耐受室温至220℃的温度两小时。
14.根据权利要求11所述的可塑覆盖物，其中所述牺牲透镜包括不透明聚酯膜。
15.根据权利要求14所述的可塑覆盖物，其中所述堆叠的最外透镜包括透明聚对苯二甲酸乙二醇酯膜。
16.一种固定于弯曲基底的凸表面上的可塑覆盖物，该可塑覆盖物包括：
具有两个或更多透镜的堆叠；
介于所述两个或更多透镜中每对相邻透镜之间的粘合剂层；
设置在所述堆叠的最外透镜上并且作为凹模腔的牺牲层，所述牺牲层包括牺牲透镜和介于所述牺牲透镜与所述堆叠的最外透镜之间的牺牲粘合剂，所述牺牲层比所述堆叠的最外透镜更不耐划伤，并且所述牺牲层比所述堆叠的最外透镜更耐热，使得所述牺牲层能够承受直接施加的热量而不造成劣化，所述直接施加的热量如果直接施加到所述堆叠的最外透镜的话，则会导致所述堆叠的最外透镜的劣化，其中所述牺牲层和所述两个或更多透镜的堆叠一起适形于所述弯曲基底的形状。
17.根据权利要求16所述的可塑覆盖物，其中所述牺牲透镜包括双轴取向的聚对苯二甲酸乙二醇酯膜。
18.根据权利要求17所述的可塑覆盖物，其中所述双轴取向的聚对苯二甲酸乙二醇酯膜能够耐受室温至220℃的温度两小时。
19.根据权利要求16所述的可塑覆盖物，其中所述牺牲透镜包括不透明聚酯膜。
20.根据权利要求19所述的可塑覆盖物，其中所述堆叠的最外透镜包括透明聚对苯二甲酸乙二醇酯膜。
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