CN116209705A - 具有遮蔽区域的复合膜 - Google Patents
具有遮蔽区域的复合膜 Download PDFInfo
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Abstract
本发明涉及一种具有遮蔽区域的包括聚乙烯醇缩醛的复合膜,所述遮蔽区域设置在载体膜上。
Description
本发明涉及一种具有遮蔽区域的包括聚乙烯醇缩醛的复合膜,所述遮蔽区域设置在载体膜上。
包括聚乙烯醇缩醛的层间膜长期以来被称为用于层叠玻璃的粘合剂层。特别地,增塑的聚乙烯醇缩丁醛(PVB)膜广泛用作玻璃-玻璃层叠体的粘合剂层,例如用于汽车使用中的挡风玻璃。
还已知在挡风玻璃的某些区域中使用对可见光不透明的层间膜以保护机械地连接挡风玻璃与底盘(chassis)的密封件或粘合剂免受UV辐射,并且为了美观原因而隐藏传感器系统以免被从交通工具(vehicle)外部看到。
进一步已知的是,使用相当薄的不透明塑料膜的贴片(patch)与普通的增塑的PVB膜组合来引入这种遮蔽。例如,WO 2019/038043 A1公开了具有印刷的遮蔽区域的薄的、非增塑的PVB膜。
然而,在工业中仍然需要改进的手段来提供具有遮蔽区域的层叠玻璃,特别是用于交通工具的挡风玻璃。
因此,本发明的目的为提供一种具有改善的特性的具有遮蔽区域的膜,其中所述改善包括更好的加工性,尤其是在印刷期间以及在储存和/或运输期间,更低的制造成本和/或更高的光学品质,尤其是在光学缺陷如皱褶、气泡或颗粒方面,更少的雾度和/或更少的黄度。
本发明已经解决了这些问题和其它问题。
在第一方面,本发明涉及一种复合膜,其包括含有聚乙烯醇缩醛和可选的增塑剂的膜A;和载体膜,其中膜A设置有遮蔽区域。
单独的膜(separate film)中规定的增塑剂和其它成分的含量的量以及所有尺寸如厚度和表面粗糙度应当是指“层叠前”的状态,即是指膜A和膜B彼此接触前的状态。
术语“遮蔽区域”是指膜A的在可见光谱(380~780nm)中的光透射率小于10%的区域。在一种变型中,遮蔽区域可以例如以虚线区域或梯度的形式向透明褪色,或者遮蔽区域可以设置有在其中嵌入的透明区域,例如为照相机提供观察区域。在这样的变型中,至少部分的遮蔽区域在可见光谱中的光透射率应小于10%。
术语“复合膜”应表示包括至少两个单独的层的膜,其中在制造期间,一个膜沉积在另一个膜上。在本发明的上下文中,优选通过溶剂浇铸(solvent casting)、将膜A沉积到载体膜上。
对于均匀的遮蔽区域,即其中遮蔽区域不褪色或不具有点状图案,可以在制造复合膜前将着色剂(颜料或染料)添加至本体(bulk)聚乙烯醇缩醛原料。
然而,优选的是,遮蔽区域通过在膜A的不面向载体膜的表面上的印刷的或涂布的墨层来设置。该优选的实施方案允许提供更复杂的图案,如点状区域或褪色,例如从黑色到灰色或从黑色到透明。
载体的材料可以选自与聚乙烯醇缩醛以及用于提供复合膜的制造方法相容的任意材料。因此,载体材料可以是玻璃或金属。然而,优选使用选自由聚乳酸、丙烯腈-丁二烯-苯乙烯共聚物、聚酰胺类、聚碳酸酯类、聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸乙二醇酯共聚物、聚羟基脂肪酸酯类、聚氨酯类、聚烯烃类如聚乙烯或聚丙烯、丙烯腈苯乙烯丙烯酸酯、聚丙烯酸酯类和聚甲基丙烯酸酯类、聚乙烯醇、TAC(三醋酸纤维素)组成的组中的聚合物材料。最优选地,载体包含聚对苯二甲酸乙二醇酯(PET),并且具体地,载体是由PET组成的膜。
优选地,载体膜的厚度为10~500μm,更优选25~250μm,并且最优选50~100μm。
还优选地,膜A以0.05~10N/3cm、优选0.1~5N/3cm并且最优选0.5~3N/3cm的粘合强度粘附至载体膜。
已经发现,使用具有该粘合强度和该载体膜厚度范围的复合膜允许提供具有遮蔽区域的非常薄的膜A。膜A应当尽可能薄,这是因为它通常被切割成形,并且仅用作挡风玻璃的某些区域中的贴片。在切割的一种变型中,膜A通过钢模或通过激光来切割,而载体完好无损(也称为吻切(kiss-cut))。因此,由于载体膜赋予的稳定效果和保护,印刷的部分可以被切割成最终的尺寸和轮廓,并且不会受到损坏或污染,而对于非常薄的膜,切割不具有载体的自支撑(free-standing)膜A将是极其困难的。然而,膜A越薄越好,这是因为其导致用于层叠的组合的层间膜的总厚度的变化越小。
优选地,膜A的厚度为5~100μm,更优选10~50μm,并且具体地为20~40μm。
如果要印刷或要涂布膜A的表面,则具有光滑的待印刷表面以提供均匀的印刷图案是有利的。然而,膜A的未被印刷或未被涂布的相反位置有利地具有一定的粗糙度RZ。该粗糙度允许在层叠期间改善脱气,以及它允许膜A的贴片更容易处理,因为其在层叠之前更少粘到玻璃或增塑的聚乙烯醇缩醛膜B。
现在已经发现,载体的一定粗糙度Rz允许制造具有一个非常光滑的表面和一个具有一定粗糙度的表面的膜A,特别是当使用溶剂浇铸方法时。膜A的表面的一定粗糙度可以通过选择具有互补的粗糙度的载体来调节,而膜A的另一表面由于溶剂浇铸膜的制造条件而非常光滑。
优选地,在将膜A的要涂布的或要印刷的表面涂布或印刷之前测量的、所述表面的表面粗糙度Rz为0.01~10μm,优选0.1~3.0μm。
还优选地,在载体膜与膜A接触之前测量的、载体膜在与膜A接触的表面上的表面粗糙度Rz为1.0~10μm,优选2.0~6.0μm。
印刷层或涂布层包含无机或有机颜料,其不应溶解于聚乙烯醇缩醛中,从而防止从膜A迁移到B或从印刷层渗出。
作为颜料,优选使用炭黑、铁氧化物、聚苯胺、苝类或尖晶石颜料。颜料可以分散在载体流体如水、醇或醇和水的混合物中。
水性印刷墨优于基于有机溶剂的印刷墨,因为它们不会溶胀或溶解膜A和/或导致膜缺陷。如果涂层薄和/或干燥步骤快,使得溶剂不会迁移到PVB膜中,则可以使用基于有机溶剂的印刷墨。
印刷墨可以通过印刷工业中公知的技术如胶版印刷、轮转凹版印刷、柔性版印刷和丝网印刷来配制和应用,随后通常是干燥步骤。
根据印刷技术和所需的不透明度,印刷层的干膜厚度为1~50μm。干膜厚度通常为2~20μm。足够高的总干膜厚度可以通过依次印刷/涂布步骤的重复来重叠墨层而实现。
优选地,墨包括选自由乙烯基吡咯烷酮、水溶性丙烯酸系树脂、醇溶性树脂,例如酚醛树脂、丙烯酸系树脂、苯乙烯-马来酸树脂、苯乙烯丙烯酸酯树脂、聚氨酯树脂、聚乙烯醇缩醛树脂、聚乙烯醇树脂或酮树脂组成的组中的一种以上的粘结剂,最优选墨包括聚氨酯树脂粘结剂。
膜A可以包含碱金属离子;钾或钠或锂为优选的。在锂的情况下,碱金属离子的优选浓度范围为7~210ppm,优选14~140ppm,并且更优选21~140ppm;在钠的情况下,碱金属离子的优选浓度范围为23~690ppm,优选46~460ppm,并且更优选69~460ppm;在钾的情况下,碱金属离子的优选浓度范围为39~1170ppm,优选78~780ppm,并且更优选117~780ppm。此外,优选以具有1~10个碳原子的羧酸盐的形式添加碱金属离子。特别优选的是乙酸钾作为粘合控制剂(adhesion control agent)。
基于膜A的重量,碱金属盐的总量可以低至0.005重量%。碱金属盐的优选范围为0.01%~0.1%;0.02~0.08%;0.03~0.06%,各重量%基于膜A的重量。
在本发明的层叠体中使用的膜A可以另外包括碱土类离子,但是由于它们对粘附性的影响是有限的,因此与碱离子相比,应该使用相对少量的碱土类离子。在本发明的第一实施方案中,膜A包括0~100ppm碱土类离子,优选10~50ppm。
本发明的层叠体中使用的膜A也可以仅包括碱土类离子作为粘合控制剂,即膜A不包括任何碱金属离子。在该情况下,碱土金属离子的浓度为500~5000ppm,优选750~4000ppm,并且更优选1500~3000ppm。镁离子是特别优选的,并且可以以羧酸镁盐的形式如乙酸镁和/或新酸镁(magnesium neoate)添加。
为了避免混浊,可以减少膜A中的氯离子和/或硝酸根离子和/或硫酸根离子的量。
因此,膜A的氯化物含量可以小于150ppm,优选小于100ppm,并且特别小于50ppm。在理想情况下,膜A的氯化物含量小于10ppm或甚至0ppm。
膜A的硝酸盐含量任选地可以小于150ppm,优选小于100ppm,并且特别小于50ppm。在理想情况下,膜A的硝酸盐含量小于10ppm或甚至0ppm。
同样任选地,膜A的硫酸盐含量可以小于150ppm,优选小于100ppm,特别小于50ppm。在理想情况下,膜A的硫酸盐含量小于10ppm或甚至0ppm。
本发明的另一方面涉及不具有载体的自支撑膜A。它可以通过从膜A剥离载体而获得。因此,本发明的一个实施方案为含有聚乙烯醇缩醛和可选的增塑剂的膜A;其中膜A的一个表面设置有通过印刷的或涂布的墨层设置的遮蔽区域,并且其中膜A通过从膜A剥离载体而获得。
有数种方法将本发明的复合膜与标准(=增塑的)聚乙烯醇缩醛膜B一起用于制造层叠的挡风玻璃。以一种简单的方式,在用于层叠方法的玻璃和夹层的最终组装之前,通过切割成一定尺寸、堆叠、附着到标准聚乙烯醇缩醛膜B的表面或附着到内玻璃表面之一,除去载体膜,并且可以制备用于层叠的剥离的印刷膜A。
选择性地,复合膜可以在如切割、堆叠和附着到载体膜材料(如PET)的其中更厚、更少弹性和更高熔融性能被证明有利的表面的步骤中一起加工。即使厚度小于40μm的膜A也可以安全地处理,直至仅在组装步骤之前不久或甚至在组装步骤期间除去载体膜。还可以从载体膜除去膜A的不需要的切割部分/框架,并且只留下最终尺寸的印刷部分附着在其上。可以将这种印刷的“贴纸”与更大片的载体膜一起定位,甚至不接触标准聚乙烯醇缩醛膜B或内玻璃表面之一上的膜A,并且利用载体膜的剥离性进行以下:1)通过施加热和压力或超声波焊接,将薄膜A的印刷表面预粘合到标准聚乙烯醇缩醛膜B的切割成尺寸的坯料(blank)的表面,2)任选地堆叠数个这样制备的组合坯料,并且用于储存,3)在层叠过程开始之前,在组装期间从“贴纸”的背面除去载体膜。
具有以“贴纸”形式附着于其上的印刷贴片的载体膜可以容易地以卷的形式储存,并且可以帮助防止墨或其它表面污染物粘附和转移到印刷膜A的背面。
因此,一个实施方案涉及一种挡风玻璃的制造方法,所述挡风玻璃包括由层间膜结合的两片玻璃,所述层间膜包括含有聚乙烯醇缩醛和可选的增塑剂的膜A;和含有聚乙烯醇缩醛和至少22重量%的量的增塑剂的膜B;所述方法依次包括以下步骤:
a)将根据权利要求1至10中任一项所述的复合膜定位至第一玻璃片,其中膜A面向第一玻璃片;
b)将载体膜从膜A剥离;和
c)将膜B定位在膜A上或第二玻璃片上;和
d)提供依次包括第一玻璃片-膜A-膜B-第二玻璃的层的叠层;
e)将在步骤d)中获得的叠层层叠以制造挡风玻璃。
本发明的另一个实施方案涉及一种挡风玻璃的制造方法,所述挡风玻璃包括由层间膜结合的两片玻璃,所述层间膜包括含有聚乙烯醇缩醛和可选的增塑剂的膜A;和含有聚乙烯醇缩醛和至少22重量%的量的增塑剂的膜B;所述方法依次包括以下步骤:
a)将根据权利要求1至10中任一项所述的复合膜定位至膜B,其中膜A面向膜B;
b)将载体膜从膜A剥离;
c)提供依次包括第一玻璃片-膜A-膜B-第二玻璃的层的叠层;和
d)将在步骤c)中获得的叠层层叠以制造挡风玻璃。
本发明的又一个实施方案涉及一种挡风玻璃的制造方法,所述挡风玻璃包括由层间膜结合的两片玻璃,所述层间膜包括含有聚乙烯醇缩醛和可选的增塑剂的膜A;和含有聚乙烯醇缩醛和至少22重量%的量的增塑剂的膜B;所述方法依次包括以下步骤:
a)提供根据权利要求2至10中任一项所述的复合膜,并且将载体膜从膜A剥离;
b)将膜A定位在第一玻璃片上,其中膜A的具有印刷或涂布的墨层的表面远离第一玻璃片;
c)将膜B定位在膜A上或第二玻璃片上;
d)提供依次包括第一玻璃片-膜A-膜B-第二玻璃的层的叠层;和
e)将在步骤c)中获得的叠层层叠以制造挡风玻璃。
当将膜A的印刷区域与任一玻璃表面上的陶瓷印刷相组合时,定位任务需要高的精度。为此,印刷的贴片可以由人工操作者移动到期望的位置,人工操作者手动地将贴片的印刷特征与玻璃上的印刷特征对准。这种对准可以单独对贴片(带有或不带有载体膜)进行,也可以将贴片附着到或不附着到常规PVB膜(膜B)的更大的坯料上进行。在另一步骤中,第二玻璃的边缘也可以与第一玻璃的边缘对准,因为这在工业中是常见的。可以使用光学系统来促进对准任务。作为一个实例,这种光学系统可以包括投射在常规PVB上的激光点和作为主要设计的一部分印刷在膜A上的定位标记,或者包括在最终产品中被陶瓷熔块(ceramic frit)隐藏的位置。定位标记也可以是膜A的完全印刷的区域内的未印刷的透明特征。然后使用照相机系统来监视激光点和定位标记的良好对准。在所描述的对准的另一种变型中,可以使用机器人从堆叠中自动地拾取各个贴片(带有或不带有载体膜),在任选的按压、超声或热焊的情况下将其放置在玻璃表面或常规PVB上的正确位置中,以在将下一层(即,常规PVB或玻璃片)置于其上之前将其充分地固定至基材。这种机器人可以使用吸盘(suction cup)来提升和移动贴片和或PVB片上的贴片。机器人还可以提供第一叠层(lay-up),并且第二机器人可以通过移动贴片、PVB片上的贴片或PVB之下或之上的陶瓷印刷玻璃来提供精确对准。在本发明的优选变型中,机器人拾取被切割成最终形状的印刷膜A,该印刷膜A仍然附着至载体膜,并且具有已经剥离的任何周围基体。然后,机器人将带有载体膜的印刷贴片定位在已经放置在第一玻璃片上的常规PVB片上,使得印刷面与PVB片接触,施加热焊点,使得当机器人臂再次向上移动时,载体膜可以从印刷贴片的背面剥离,并且该贴片保持预先粘附在PVB片的表面上。为了最终定位,将整个PVB片然后小心地在第一玻璃片上移动,直至与该玻璃片上的陶瓷印刷达到最佳匹配。在此之后,施加另外的层和第二玻璃片。
在另一个方面,本发明涉及一种挡风玻璃或通常为层叠玻璃部件,其在上述方法中之一获得。
根据本发明使用的膜A和膜B含有聚乙烯醇缩醛,其通过聚乙烯醇或乙烯-乙烯醇共聚物的缩醛化来制造。
膜可以包含聚乙烯醇缩醛类,每种聚乙烯醇缩醛具有不同的聚乙烯醇含量、缩醛化度、残余乙酸酯含量、乙烯比例、分子量和/或缩醛基团的醛的不同链长。
特别地,用于制造聚乙烯醇缩醛的醛类可以为包含2~10个碳原子的直链或支链(即,“正(n)”或“异(iso)”型),这导致相应的直链或支链缩醛基团。聚乙烯醇缩醛类因此被称为“聚乙烯醇(异)缩醛类”或“聚乙烯醇(正)缩醛类”。
根据本发明使用的聚乙烯醇缩醛特别是由至少一种聚乙烯醇与一种以上的包含2~10个碳原子的脂肪族无支链化合物(aliphatic unbranched compounds)反应得到。为此,优选使用正丁醛。
用于制造膜A或膜B中的聚乙烯醇缩醛的聚乙烯醇或乙烯-乙烯醇共聚物可以是相同或不同的、纯的或具有不同聚合度或水解度的聚乙烯醇或乙烯-乙烯醇共聚物的混合物。
膜A或膜B中的聚乙烯醇缩醛的聚乙酸乙烯酯含量可以通过使用皂化至适当程度的聚乙烯醇或乙烯-乙烯醇共聚物来设定。聚乙烯醇缩醛的极性受到聚乙酸乙烯酯含量的影响,由此增塑剂相容性和各层的机械强度也发生变化。还可以进行聚乙烯醇或乙烯-乙烯醇共聚物与多种醛类化合物的混合物的缩醛化。
膜A或膜B优选包含聚乙酸乙烯酯基团的比例相同或不同的聚乙烯醇缩醛,比例为0.1~20mol%、优选0.5~3mol%、或5~8mol%。
在膜A中使用的聚乙烯醇缩醛PA的聚乙烯醇含量可以为6~26重量%、8~24重量%、10~22重量%、12~21重量%、14~20重量%、16~19重量%,并且优选16~21重量%或10~16重量%。
独立于膜A,在膜B中使用的聚乙烯醇缩醛PB的聚乙烯醇含量可以为14~26重量%、16~24重量%、17~23重量%,并且优选18~21重量%。
在本发明的优选实施方案中,膜A包括乙烯醇基团的比例为6~26重量%的聚乙烯醇缩醛PA,并且膜B包括乙烯醇基团的比例为14~26重量%的聚乙烯醇缩醛B。
根据本发明使用的膜A和/或膜B可以包含一种以上的选自以下组的化合物作为增塑剂:
-多价脂肪族或芳香族酸的酯类,例如己二酸二烷基酯类,如己二酸二己酯、己二酸二辛酯、己二酸己基环己酯、己二酸庚酯和己二酸壬酯的混合物、己二酸二异壬酯、己二酸庚基壬酯、和己二酸与脂环族酯醇或含醚化合物的酯醇的酯类,癸二酸二烷基酯类,如癸二酸二丁酯,以及癸二酸与脂环族酯醇或含醚化合物的酯醇的酯类,邻苯二甲酸的酯类,如邻苯二甲酸丁基苄基酯或邻苯二甲酸二-2-丁氧基乙酯。
-多价脂肪族或芳香族醇或低聚醚二醇与一个以上的直链或支链的脂肪族或芳香族取代基的酯类或醚类,例如甘油类、二甘醇类、三甘醇类或四甘醇类与直链或支链脂肪族或脂环族羧酸的酯类;后一组的实例包括二甘醇-双-(2-乙基己酸酯)、三甘醇-双-(2-乙基己酸酯)、三甘醇-双-(2-乙基丁酸酯)、四甘醇-双-正庚酸酯、三甘醇-双-正庚酸酯、三甘醇-双-正己酸酯、四甘醇-二甲醚和/或二丙二醇苯甲酸酯
-具有脂肪族或芳香族酯醇的磷酸酯类,如磷酸三(2-乙基己基)酯(TOF)、磷酸三乙酯、磷酸二苯基-2-乙基己酯和/或磷酸三甲苯酯
-柠檬酸、琥珀酸和/或富马酸的酯类。
根据定义,增塑剂为具有高沸点的有机液体。为此,沸点高于120℃的其它种类的有机液体也可以用作增塑剂。
然而,膜A优选不含任何添加的增塑剂。
本发明对于包括薄玻璃片的层叠体也是有利的,因为在薄玻璃上烧结瓷釉(enamel)甚至更容易制造具有光学缺陷的不合规格的弯曲板。在本发明的优选实施方案中,至少一个玻璃片的厚度小于2.1mm,如1.8mm,小于1.8mm;小于1.6mm;小于1.4mm;小于1.0mm;或小于0.9mm。术语“玻璃片”应理解为可用于制造挡风玻璃的任何材料,包括聚碳酸酯板。
根据本发明使用的含有增塑剂的膜B在层叠之前的起始状态下包含至少22重量%,如22.0~45.0重量%,优选25.0~32.0重量%,并且特别为26.0~30.0重量%的增塑剂。
膜A或膜B优选包含聚乙酸乙烯酯基团的比例相同或不同的聚乙烯醇缩醛,比例为0.1~20mol%、优选0.5~3mol%、或5~8mol%。
膜B在起始状态下的厚度为450~2500μm,优选600~1000μm,优选700~900μm。在本发明中可以使用多个膜B,相互堆叠或由膜A隔开。
如果将膜B在制造夹层结构(sandwich)之前拉伸和/或另外以弯曲的方式适应屏幕(例如挡风玻璃)的形状,则在层叠时的规定厚度可以再次减少高达20%。
另外,膜A和膜B可以包含其它添加剂,如残留量的水、UV吸收剂、抗氧化剂、粘合调节剂、荧光增白剂或荧光添加剂、稳定剂、着色剂、加工助剂、无机或有机纳米颗粒、热解硅酸(pyrogenic silicic acid)和/或表面活性物质。
特别地,膜B可以包含0.001~0.1重量%的羧酸的碱金属盐和/或碱土盐作为粘合控制剂。优选的是,膜B包含至少10ppm、优选20ppm、并且最优选30ppm的量的镁离子。
优选进行用于制造层叠玻璃的层叠步骤,使得膜A和B定位于两个玻璃片之间,并且在升高或降低的压力和升高的温度下按压由此制备的层压体(layered body)以形成层叠体。
为了层叠层压体,本领域技术人员熟悉的方法可以在预先制造预层叠体(pre-laminate)的情况下使用,也可以在不预先制造预层叠体的情况下使用。
所谓的“高压釜方法”在约10~15巴的升高的压力和100~150℃的温度下进行约2小时。真空袋或真空环方法,例如根据EP 1 235 683 B1,在大约200毫巴和130~145℃下起作用。
也可使用真空层压机。这些包括可以加热和抽真空的腔室,其中层叠玻璃可以在30~60分钟内层叠。0.01~300毫巴的减压和100~200℃的温度,特别是130~160℃,已经证明了它们在实践中的价值。
膜B也可以具有楔形厚度轮廓。根据本发明的层叠玻璃层叠体获得楔形厚度轮廓,甚至具有膜A的平面平行的厚度轮廓,并且可以用于HUD显示器用机动车辆(motorvehicle)挡风玻璃。
根据本发明的层叠玻璃可以用于汽车、公共汽车、卡车、轮船、火车或飞机的挡风玻璃、尾灯和侧装玻璃(back-lights and side glazing)。
实施例
复合膜的制备
使用厚度为50μm的具有无光泽表面(matt surface)的聚对苯二甲酸乙二醇酯(PET)膜(等级#50-X42G,可从Toray Industries,Inc.商购获得)作为载体。表面粗糙度(Rz)为4.0μm。
在狭缝模头涂布模式中使用包括退绕机、涂布机、干燥机和卷绕机的市售标准溶剂涂布设备。基材速度为1.1m/分钟,并且移动基材上的润湿厚度为200μm。在26℃的温度下进行涂布。涂布唇(coating lip)和移动基材之间的间隙为300μm。
干燥分三个部分进行,并且干燥部分中的各温度分别设定为60℃、70℃和125℃。总干燥时间约为4分钟。
将包含PVB膜A和PET载体的复合膜卷绕成卷。用肉眼检查时,在复合膜上没有发现褶皱。将载体从复合物样品上剥离以测量干燥膜A的厚度。测量显示膜A具有厚度为25μm。
从复合膜上切下一组5个3cm宽和15cm长的试样,并且用拉伸试验机在20℃和500mm/分钟的拉伸速度下测量t-剥离粘合强度。5次测量的平均值为1.5N/3cm。
印刷到复合膜上
在以下印刷过程中使用第一步骤中使用的复合膜。
在印刷过程中使用包含炭黑系颜料和聚氨酯系粘结剂的水性印刷墨。印刷墨的粘度为20DIN-秒(20℃,DIN 4mm杯)。
使用柔性版印刷机将印刷墨施加至复合膜的膜A。在第一步骤中,复合膜通过在线电晕处理单元以改善膜A表面上的墨粘附性。然后,电晕处理膜通过四个印刷单元,这四个印刷单元都装配有柔性的Kodak Flexcel NX凸版。此外,第一印刷单元装配有Zecher160L/cm,10g/m2(60°)的网纹辊,第二印刷单元装配有Zecher 220L/cm,10g/m2(60°)的网纹辊,第三印刷单元装配有Apex 180L/cm,12g/m2(开放式)的网纹辊,并且第四印刷单元装配有Zecher120L/cm,20g/m2(60°)。印刷单元中的干燥温度设定为55℃。在通过印刷单元后,复合膜还通过另外的干燥区(4m),该干燥区设定为70℃。在整个印刷过程中,复合膜以大约80m/分钟的速度通过印刷机。
在印刷过程结束时,将复合膜缠绕在直径为6英寸的PVC卷芯上。
由于PET载体膜,没有未干燥的墨转移到卷绕的聚合物膜卷中的PVB膜的底侧。经干燥的墨在PVB基材上形成均匀封闭的层(干膜厚度为约7μm),其在目视检查后呈现为完全不透明。用透射密度计(x-rite,型号331C)测量干燥的墨层的光密度,其大于3.5。
Claims (15)
1.一种复合膜,其包括含有聚乙烯醇缩醛和可选的增塑剂的膜A;和
载体膜,
其中膜A设置有遮蔽区域。
2.根据权利要求1所述的复合膜,其中所述遮蔽区域通过膜A的不面向所述载体膜的表面上的印刷的或涂布的墨层来设置。
3.根据权利要求1或2所述的复合膜,其中所述载体膜包含选自由聚乳酸、丙烯腈-丁二烯-苯乙烯共聚物、聚酰胺类、聚碳酸酯类、聚对苯二甲酸乙二醇酯、聚对苯二甲酸乙二醇酯共聚物、聚羟基脂肪酸酯类、聚氨酯类、聚烯烃类如聚乙烯或聚丙烯、丙烯腈苯乙烯丙烯酸酯、聚丙烯酸酯类和聚甲基丙烯酸酯类、聚乙烯醇、TAC(三醋酸纤维素)组成的组中的聚合物,优选所述载体包含聚对苯二甲酸乙二醇酯。
4.根据权利要求1至3中任一项所述的复合膜,其中所述膜A的厚度为15~40μm。
5.根据权利要求1至4中任一项所述的复合膜,其中所述载体膜的厚度为25~250μm。
6.根据权利要求1至5中任一项所述的复合膜,其中膜A以0.05~10N/3cm的粘合强度粘附至所述载体膜。
7.根据权利要求2至6中任一项所述的复合膜,其中在将膜A的要涂布的或要印刷的表面涂布或印刷之前测量的、所述表面的表面粗糙度Rz为0.01~10μm,优选0.1~3.0μm。
8.根据权利要求1至7中任一项所述的复合膜,其中在所述载体膜与所述膜A接触之前测量的、所述载体膜在与膜A接触的表面上的表面粗糙度Rz为1.0~10μm,优选2.0~6.0μm。
9.根据权利要求1至8中任一项所述的复合膜,其中墨包括选自由乙烯基吡咯烷酮、水溶性丙烯酸系树脂、醇溶性树脂,例如酚醛树脂、丙烯酸系树脂、苯乙烯-马来酸树脂、苯乙烯-丙烯酸酯树脂、聚氨酯树脂、聚乙烯醇缩醛树脂、聚乙烯醇树脂或酮树脂组成的组中的粘结剂,优选所述墨包括聚氨酯树脂粘结剂。
10.一种膜A,其包含聚乙烯醇缩醛和可选的增塑剂;其中膜A的一个表面设置有通过印刷的或涂布的墨层设置的遮蔽区域,并且其中所述膜A通过从膜A剥离载体膜而获得。
11.一种根据权利要求1至10中任一项所述的复合膜的制造方法,所述方法依次包括以下步骤:
a)提供载体膜;
b)用包含溶剂、聚乙烯醇缩醛或聚乙烯基乙烯缩醛和可选的增塑剂的溶液涂布所述载体膜的一个表面;
c)蒸发所述溶剂以在所述载体膜的一个表面上获得膜A;和
d)通过用墨层印刷或涂布所述膜A的不与所述载体膜接触的表面来设置遮蔽区域。
12.一种挡风玻璃的制造方法,所述挡风玻璃包括由层间膜结合的两片玻璃,所述层间膜包括含有聚乙烯醇缩醛和可选的增塑剂的膜A;和含有聚乙烯醇缩醛和至少22重量%的量的增塑剂的膜B;所述方法依次包括以下步骤:
a)将根据权利要求1至10中任一项所述的复合膜定位至第一玻璃片,其中所述膜A面向所述第一玻璃片;
b)将载体膜从所述膜A剥离;和
c)将所述膜B定位在所述膜A上或第二玻璃片上;和
d)提供依次包括第一玻璃片-膜A-膜B-第二玻璃的层的叠层;
e)将在步骤d)中获得的叠层层叠以制造挡风玻璃。
13.一种挡风玻璃的制造方法,所述挡风玻璃包括由层间膜结合的两片玻璃,所述层间膜包括含有聚乙烯醇缩醛和可选的增塑剂的膜A;和含有聚乙烯醇缩醛和至少22重量%的量的增塑剂的膜B;所述方法依次包括以下步骤:
a)将根据权利要求1至10中任一项所述的复合膜定位至所述膜B,其中所述膜A面向所述膜B;
b)将载体膜从所述膜A剥离;
c)提供依次包括第一玻璃片-膜A-膜B-第二玻璃的层的叠层;和
d)将在步骤c)中获得的叠层层叠以制造挡风玻璃。
14.一种挡风玻璃的制造方法,所述挡风玻璃包括由层间膜结合的两片玻璃,所述层间膜包括含有聚乙烯醇缩醛和可选的增塑剂的膜A;和含有聚乙烯醇缩醛和至少22重量%的量的增塑剂的膜B;所述方法依次包括以下步骤:
a)提供根据权利要求2至10中任一项所述的复合膜,并且将载体膜从所述膜A剥离;
b)将所述膜A定位在第一玻璃片上,其中所述膜A的具有印刷或涂布的墨层的表面远离所述第一玻璃片;
c)将所述膜B定位在所述膜A上或第二玻璃片上;
d)提供依次包括第一玻璃片-膜A-膜B-第二玻璃的层的叠层;和
e)将在步骤c)中获得的叠层层叠以制造挡风玻璃。
15.一种挡风玻璃,其通过根据权利要求12、13或14所述的方法来获得。
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EP20198614.8A EP3974181A1 (en) | 2020-09-28 | 2020-09-28 | Composite films with an obscuration area |
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PCT/EP2021/076320 WO2022063962A1 (en) | 2020-09-28 | 2021-09-24 | Composite films with an obscuration area |
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