CN1481306B - 汽车窗玻璃 - Google Patents

汽车窗玻璃 Download PDF

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CN1481306B
CN1481306B CN01820785.5A CN01820785A CN1481306B CN 1481306 B CN1481306 B CN 1481306B CN 01820785 A CN01820785 A CN 01820785A CN 1481306 B CN1481306 B CN 1481306B
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布赖恩·E·克里弗
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Pilkington Group Ltd
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
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    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
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    • Y10T428/31645—Next to addition polymer from unsaturated monomers
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Abstract

一种汽车用窗玻璃(10)，包括退火玻璃或者半钢化玻璃(12)的单玻璃层，该窗玻璃具有塑料膜(16)，该塑料膜用接触粘合剂(14)粘贴在该玻璃层的主要表面上。

Description

汽车窗玻璃
技术领域
本发明涉及汽车窗玻璃。本发明具体涉及结构新颖的汽车窗玻璃。
背景技术
汽车用窗玻璃常规包括层合的安全玻璃(广泛用作挡风玻璃)或者钢化的安全玻璃(广泛用作侧窗玻璃和后窗玻璃)。层合的挡风玻璃通常包括两层退火玻璃层(即已受到可控冷却处理而除去其内应力的玻璃)，各个玻璃层的厚度为2.1mm，这两个玻璃层在高温和高压下(例如145℃和10个大气压下)用一层聚乙烯醇缩丁醛粘贴在一起。钢化玻璃的形成方法是将退火的玻璃进行冷淬处理，以便在玻璃中形成永久应力。汽车用钢化玻璃应该钢化到这样的程度，使得它能够通过ECE R43(欧洲汽车窗玻璃高级安全标准)中规定的均匀钢化玻璃板的碎裂测试，在这种测试中，5cm×5cm见方的碎片数目不小于40片或者大于400片，或者在玻璃厚度不超过3.5mm的情况下，大于450片。
1995年由“汽车工程学会”出版的题为“双层窗玻璃：未来汽车改进方案想法”的技术论文公开了另一种汽车用的窗玻璃，即双层窗玻璃，该窗玻璃包括粘贴在至少一个塑料层上的单层玻璃。该论文公开了用于汽车用的窗玻璃，该窗玻璃包括单层玻璃，该层玻璃是退火的或者钢化的，粘贴在厚度为0.8-1.0mm的聚氨酯塑料板上。这种窗玻璃比常规的安全玻璃具有更多优点，然而它的制造成本高，因为采用了常规的层合工艺(即高温高压工艺)将聚氨酯板粘贴在玻璃层上。
安全玻璃和双层窗玻璃众所周知已用在建筑工业上。然而，建筑用窗玻璃通过的标准不同于车用窗玻璃的标准，因而一般不允许用在汽车上。
汽车用层合玻璃和钢化玻璃以及已知类型的汽车双层窗玻璃的制造成本是很高的，因为设备成本和工艺成本很高。因此迫切需要降低适合用在汽车上的窗玻璃成本。
发明内容
我们已经发现，结构不同于常规安全玻璃和其它已知汽车窗玻璃的窗玻璃适合用在汽车上。
按照本发明的一个方面，提供了一种汽车用窗玻璃，包括单层的半钢化玻璃，该玻璃层上具有塑料膜，该膜利用接触粘合剂粘贴在玻璃层的主要表面上。在这种汽车用窗玻璃中，在粘贴塑料膜之前对单层玻璃进行ECE R43中规定的均匀钢化玻璃板的破裂测试时，该单层玻璃将碎裂，使得5cm×5cm见方的碎片数目小于40片。
采用接触粘合剂(这种粘合剂涂在要粘贴的两个表面中的至少一个表面上；然后将两个表面合在一起，在它们之间加压短时间，即可达到快速粘贴)将塑料膜粘贴在玻璃上可以避免使用常规的层合工艺，由此降低制造成本。
令人意外的是，这种窗玻璃适合于用在汽车上，因为曾认为，在汽车用窗玻璃厚度状态下(高到约6mm厚度)，钢化程度不足以通过ECE R43中规定的均匀钢化玻璃板碎裂测试的玻璃(即退火玻璃和半钢化玻璃)不可能通过ECE R43的冲击测试。曾经预料，在这种测试中，对窗玻璃进行这些测试时，塑料膜将会由破裂玻璃的锋利碎片撕开或者撕裂，因此这种玻璃不会通过测试。然而，我们发现，尽管玻璃碎裂成锋利碎片，但它们并不撕开或撕裂塑料膜，因此这种玻璃通过了测试。
该塑料膜的厚度最好至少为50微米，并且可以为单层或者多层结构。该塑料膜最好包括聚对苯二甲酸乙二酯。
可以在塑料膜露出的一侧涂上硬化层(一种抗擦伤和画痕的硬化层)，以增强玻璃的使用寿命。该粘接剂的厚度在5-50微米的范围内，最好涂在塑料膜的表面上。将塑料膜从玻璃上剥离下来所需的力小于33N。
该玻璃层包括半钢化的玻璃。在窗玻璃预定用作汽车侧窗时，希望采用半钢化的玻璃，需要这种玻璃承受用力关门造成的冲击。该玻璃的厚度至少为1mm比较好，最好至少为1.5mm，以提高抗石块撞击的能力。
该窗玻璃还具有控制阳光的特性。例如，该窗玻璃可以在膜上或者玻璃上沉积一层红外光反射材料。该窗玻璃还可以包括一层吸收紫外光的材料。
该窗玻璃最好包括侧窗玻璃、后窗玻璃和顶窗玻璃。
按照本发明的另一方面，提供了一种汽车窗玻璃，包括有半钢化玻璃的单层玻璃，该窗玻璃具有塑料膜，该塑料膜粘贴在玻璃层的主要表面上，其中，塑料膜粘贴在玻璃上的粘贴程度是使得从玻璃上将膜剥离下来所需要的力小于33N。在这种车用窗玻璃中，该单层玻璃在粘贴于塑料膜之前对其进行ECE R43中规定的均匀钢化玻璃板碎裂测试时，该单层玻璃将碎裂，其中任何5cm×5cm见方的碎片数目小于40。
附图说明
下面参考附图说明本发明的实施例，这些附图是：
图1是局部截面图，示出本发明的双层窗玻璃；
图2是示意图，示出用来测量将膜剥离玻璃样品所需力的装置；
图3和4是曲线图，示出将塑料膜剥离玻璃样品所需的力。
具体实施方式
下面参照附图，双层窗玻璃总的用编号10表示，它包括具有主要表面12a和12b的退火玻璃层12。当对退火玻璃板进行ECE R43规定的均匀钢化玻璃板碎裂测试时，该玻璃将碎裂，并且任何5cm×5cm见方的碎片数目小于40片。利用包含接触粘接剂的粘接剂层14将退火玻璃层粘贴在聚对苯二甲酸乙二酯(PET)的薄膜16上。该PET膜通常可以从许多厂家买到，可以为单层膜或者多层膜，这种膜经常涂有一层接触粘剂的薄层，该粘接剂层的厚度通常为25微米，涂在薄膜的一个表面上，该粘接剂层受到抗粘层的保护。在这种窗玻璃结构中该抗粘层可以从PET膜上取下来，然后将膜放在玻璃板的上面，使膜的粘接剂一侧对着玻璃表面12a。然后将膜和玻璃合起来，并将其送入一对辊子之间，该对辊子用于在膜和玻璃之间施加压力，使得粘接剂将膜粘贴在玻璃上。
已经用厚度为2.1mm的退火玻璃和厚度为200微米的双层PET薄膜按上述方法制作双层窗玻璃的样品，该PET薄膜是从CourtauldsPerformance Films(CP film)公司买的，该薄膜的粘接剂层厚度为25微米，该粘接剂涂在一个表面上。对尺寸为300mm×300mm的样品进行了ECE R43的落球测试，并通过了这种测试。对尺寸为1100mm×500mm的另一个样品进行了ECE R43的headform的测试，并通过了该测试。
还用同样方法制作了另一组样品，只是所用的PET薄膜是从3M公司买的200微米厚的三层薄膜，在PET薄膜的一个表面上具有25微米厚的粘接剂层。已经发现，尺寸为300mm×300mm的样品可以通过ECE R43的落球测试，尺寸为1100mm×500mm的样品可以通过ECER43的headform的测试。还通过将这种3M膜贴在3mm和4mm厚的退火玻璃上做成尺寸为300mm×300mm的其它一些样品，其中各个样品均通过了ECE R43的落球测试。
已经制作了另一组样品，用的是2.1mm厚的退火玻璃，但是在这些样品中，PET膜是从Madico公司买的150微米厚的单层膜，该膜的一个表面上具有25微米厚的粘接剂层，该粘接剂在薄膜和玻璃之间加压前用水湿润。湿润的方法是将水喷在玻璃表面上，然后将玻璃和薄膜合在一起，并利用橡胶辊在薄膜和玻璃之间加压，这种橡胶棍还可以赶走薄膜和玻璃之间的空气以及过量的水。已经显示，这种尺寸为300mm×300mm的窗玻璃样品可以通过ECE R43的落球测试。
这些测试结果是令人意外的，因为退火玻璃在大多数车用窗玻璃的厚度(即约3mm-6mm)下，在进行ECE R43的落球和headform两个测试时均破裂成很锋利的碎片，虽然PET膜具有很高的抗张强度，但是它的抗撕裂性相当差，所以曾预料，在进行各种测试时该PET膜将会由测试玻璃窗形成的很锋利的碎玻璃片撕开或者撕裂。然而，没有发生这种情况，在各个上述例子中玻璃确实破碎成很锋利的碎片，但是它们没有撕开或者撕裂PET膜。可以认为，这是由于玻璃厚度和PET膜粘贴在玻璃上的粘贴程度的联合作用的结果。厚度为4mm或者更小的玻璃层尽管是刚性的，但也是相对薄的，薄到足以在受撞击发生玻璃破碎之前可以稍微弯曲，因此可以吸收一些撞击能量。另外可以认为，双层窗玻璃的冲击性能在某种程度上可以由PET膜粘合在玻璃上的粘接程度决定。可以认为，粘接程度越高，窗玻璃越容易碎。粘接程度太高的窗玻璃将使窗玻璃容易碎裂，这种窗玻璃不能充分吸收撞击在窗玻璃上的撞击能量，因此，PET膜将会由受ECE R43落球测试和headfrom测试的玻璃层玻璃破碎产生的锋利碎片撕开或者撕裂。如果粘接程度太低则不能使PET膜充分粘贴在玻璃上，因此膜可能容易从窗玻璃上剥离下来。
测量了许多样品中PET膜粘贴在玻璃上的粘贴程度。测试了尺寸为80mm×30mm的4mm厚的在其一个侧面上粘贴有PET膜的一些样品，并用将膜从样品上剥离下来所需要的力表示粘贴程度。采用Instron5500R多用测试机测量样品，垂直剥离速度(即从玻璃样品上拉出薄膜的速度)设定为300mm/min。该装置示意示于图2。其中牵引力沿垂直于玻璃表面的箭头26方向作用于膜上。样品可以沿箭头20的方向在辊子22和24的下面运动，以确保牵引力相对于玻璃表面以恒定的角度作用。结果示于图3和4。图3中的样品是上述CP膜粘贴在玻璃上的样品，而图4中的样品是上述3M膜粘贴在玻璃上的样品。这些结果显示出，一般说来，开始剥离时比继续剥离时需要的作用力大。对于CP膜，将膜从玻璃上剥离下来所需要的力在约15-23N的范围内，而对于3M膜，这一范围在约23-33N之间。
本发明不限于退火玻璃。本发明还适用半钢化玻璃，这种玻璃是已经钢化的但还没有达到与钢化玻璃同一钢化程度的玻璃(即在ECER43规定的均匀钢化玻璃板破裂测试中，半钢化玻璃板将碎裂，得到的5cm×5cm见方碎片的数目小于40片)。对于一定的厚度，半钢化玻璃表现出比钢化玻璃低的钢化应力。当窗玻璃预定用作汽车门侧窗时，很希望用半钢化的玻璃，需要这种玻璃承受用力关门造成的振动。
上述例子中应用了PET膜，因为这种膜容易从许多厂家买到。然而，应当看到，由其它塑料做成的膜也是适用的，这些膜包括聚萘二甲酸乙二酯、聚碳酸酯、丙烯酸、聚氨酯(包括热塑性聚氨酯，例如Dow公司生产的ISOPLAST)和离子聚合物树脂(例如Du Pont公司的SentryGlas PLUS)。塑料膜可以是单层膜或者是多层膜，其厚度至少为50微米。
在上述实施例中，涂在PET膜上的粘合剂厚度约25微米，但是应当看到粘合剂的厚度可以在5-50微米的范围内。另外，粘接剂层可以涂在玻璃表面上而不涂在膜上，或者除涂在玻璃上外还涂在膜上。还可以设想到，可以将粘合剂层喷涂、浇涂、浸涂或者网板印刷在玻璃上和/或塑料表面上。可以用已知聚合物形成粘合作用，这些聚合物是可加热固化的或者是紫外线照射固化的，当采用这些聚合物时，需要将待粘贴的表面合起来，然后在这些表面之间施加压力。
可以使窗玻璃具有控制阳光的特性，方法是在窗玻璃的玻璃表面上或者塑料层上涂一层红外光反射层和/或者将吸收红外线的物质加入到玻璃窗的玻璃上或者加入到玻璃窗的一个塑料层上。
本发明的汽车窗玻璃比现在用的汽车窗玻璃(现用最薄汽车钢化窗玻璃一般约为3mm厚)薄，所以本发明的窗玻璃重量轻，具有较大的设计灵活性。
在应用时，将窗玻璃装在汽车上，使塑料膜对着车的内部。这样可以获得附加的优点，即一旦窗玻璃破碎时，塑料层可以防止玻璃碎片和碎屑进入车内。
应当看到，还可以在塑料层的露出表面上涂上一层常规的硬化涂层(抗擦伤和画痕层)例如聚二甲基硅氧化烷层，由此可以增强窗玻璃的耐用性。

Claims (10)

1.一种汽车用窗玻璃，包括厚度为1至4mm的单层的半钢化玻璃，其中，当该窗玻璃经受ECE R43中规定的均匀钢化玻璃板的破裂测试时，该玻璃板将碎裂，且5cm×5cm见方的碎片数目小于40片，
该窗玻璃具有聚对苯二甲酸乙二酯塑料膜，该膜利用接触粘合剂粘贴在玻璃层的主要表面上，粘合剂涂在要粘贴的两个表面中的至少一个表面上，粘合剂需要将两个表面合在一起，短时间加压，以达到快速粘贴，
结果，窗玻璃通过了ECE R43的落球测试和/或头模冲击测试，并且
其中塑料膜粘贴在玻璃上的粘贴程度是使得当以300mm/min的速度从玻璃上拉下塑料膜时，从玻璃上将塑料膜剥离下来所需要的力处在15至33N的范围内。
2.如权利要求1所述的窗玻璃，其特征在于，塑料膜的厚度至少为50微米。
3.如权利要求1或2所述的窗玻璃，其特征在于，塑料膜包括单层膜。
4.如权利要求1或2所述的窗玻璃，其特征在于，该塑料膜包括多层塑料。
5.如权利要求1或2所述的窗玻璃，其特征在于，一层硬化层涂在塑料膜暴露的一侧。
6.如权利要求1或2所述的窗玻璃，其特征在于，该粘接剂的厚度在5-50微米的范围内。
7.如权利要求1或2所述的窗玻璃，其特征在于，该粘接剂涂在塑料膜的表面上。
8.如权利要求1或2所述的窗玻璃，其特征在于，还具有形成在膜上或者玻璃上的红外线反射材料层。
9.如权利要求1或2所述的窗玻璃，其特征在于，该窗玻璃的层吸收紫外光。
10.如权利要求1或2所述的窗玻璃，其特征在于，该窗玻璃是侧窗玻璃、后窗玻璃和顶窗玻璃。
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