CN1805849A - 生产曲面层压玻璃板的工艺 - Google Patents

生产曲面层压玻璃板的工艺 Download PDF

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CN1805849A
CN1805849A CNA2004800164383A CN200480016438A CN1805849A CN 1805849 A CN1805849 A CN 1805849A CN A2004800164383 A CNA2004800164383 A CN A2004800164383A CN 200480016438 A CN200480016438 A CN 200480016438A CN 1805849 A CN1805849 A CN 1805849A
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glass
interlayer
sheets
functional layer
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CN100581813C (zh
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L·博洛格内斯
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Pilkington Italia SpA
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Abstract

供汽车用的多层窗用玻璃，其中热成形一种热塑性功能薄膜，然后在插入多层窗用玻璃之间之前，通过强制通风进行冷却。

Description

生产曲面层压玻璃板的工艺
本发明涉及层压玻璃板和涉及用于制造这类层压玻璃板的方法，上述层压玻璃板包括一种透明的功能薄膜，所述功能薄膜埋置在若干层压的层之间。本发明在制造多层汽车窗玻璃，亦即，挡风玻璃，侧窗玻璃，后窗玻璃及天窗玻璃中，或者在其它可以采用曲面窗玻璃的领域中，比如在建筑业中，找到具体的应用。
层压玻璃板包括两个或多个玻璃薄板，所述两个或多个玻璃薄板与它们之间的一个夹层粘合在一起，上述夹层包括一层或多层粘合树脂，所述粘合树脂通常是聚乙烯醇缩丁醛。
玻璃通常是一种无机玻璃，但也可以使用刚性透明的有机材料如聚碳酸酯。用来粘合玻璃薄板的树脂可以提供一些安全性能，或者与一个或多个附加层形成一种粘合，上述一个或多个附加层插在各玻璃薄板之间，以便提供一种具有改善的强度、抗碎裂等性能的终端产品。
通常，将一层具有厚度是在0.2mm-1.0mm范围内，典型的是0.38mm或0.76mm的PVB或者乙烯醋酸乙烯酯加到终端产品中，比如，以便提供一种具有合格安全性能的汽车挡风玻璃。
经常，层压玻璃板还包括一层功能薄膜作为附加层与上述夹层结合，比如一种具有独特物理性能的热塑性层。最普遍的是，将这层薄膜埋置在两层或多层粘合树脂层如PVB之间，因为PVB已知比可能的功能层更好粘附到玻璃上。也可以使用具有更复杂结构的夹层，亦即两个不同的功能薄膜层或者相同的功能薄膜层，它们被一个粘合树脂内层分开，并放在两个粘合树脂外层之间。
这些功能薄膜用来赋予玻璃板一些附加的性能，如太阳能控制性能，及尤其是对于眩目波长的滤光功能，以便减少太阳能传热，或者提供加热机构或增加的安全性。
用来提供一种功能薄膜的材料的一个例子是聚对苯二甲酸乙二醇酯(PET)，也许涂装另一些分层用于达到上述附加性能。
包括用PET制成的一种功能薄膜的典型层压玻璃板比如在美国专利No.4,799,745中已有介绍。
由于将一种功能薄膜插入层压玻璃板中可能产生的困难是一种层压制品的生产，上述层压制品是透明的并且没有任何光学缺陷。常规层压工艺使用例如一层PVB作为粘合树脂，所述常规层压工艺包括在一种高压釜内部将层压制品加热到PVB树脂的软化温度，同时让树脂流动的步骤，由此形成一种没有显著光学缺陷的透明薄膜。一般，功能热塑性薄膜具有比PVB树脂高的熔点，因此在PVB软化温度下它们不会软化到同样程度。结果可以生产一种具有折痕或皱折外观的复合层压制品。
这些层压制品对大多数应用，尤其是对汽车窗玻璃来说是不合格的。这个问题对于曲面层压制品如汽车挡风玻璃，尤其是具有高度十字曲率的那些层压制品特别感觉到，此处得到一种具有皱折外观的层压制品的危险甚至更大。此外，现代化的汽车设计要求窗玻璃表面具有不断增加的曲率。
欧洲专利申请EP 877,664A介绍了一种用于生产层压玻璃板的工艺，上述层压玻璃板包括一种PET薄膜作为夹层的一部分，其中PET在层压工艺之前拉伸，以便赋予PET特殊的热收缩性能。含PET的夹层放在两个玻璃薄板之间，以便在最终层压步骤之前将任何过量部分剪掉。现已发现，这些操作手续减轻了但未完全消除起皱折问题，尤其是当层压制品是一种具有高度十字曲率的曲面层压制品时更是如此。
美国专利No.5,208,080公开了一种多层复合玻璃板，所述多层复合玻璃板具有一层功能薄膜，该功能薄膜具有比每个玻璃板都小的尺寸。围绕功能薄膜的间隙充填有一种辅助薄膜带，优选的是PVB带。现已发现，使用这种辅助薄膜带不利之处在于，在功能薄膜和辅助带的边界处，它促进形成气泡和其它畸变。
在国际专利申请公报No.WO 00/26023中，介绍了一种经过涂装的多层挡风玻璃，所述多层挡风玻璃具有一个夹层，该夹层包括一种热塑性功能薄膜，其中功能薄膜的边缘位于周边暗淡带内。
在国际专利申请公报No.WO 01/51279中所介绍的一种改进的工艺，能在不用任何辅助薄膜情况下急剧减少皱折和折痕，同时通过周边修整减少功能薄膜的尺寸，因而消除了可能的皱折，并且夹层的外部边缘位于玻璃板边缘之内。
在这种情况下，一种产生不透明或部分不透明轮廓的薄暗淡带可以掩蔽未经涂装的减小的周边区域。
无论怎样，这种轮廓可以减小(尽管很轻微)窗玻璃的透明表面，并且当终端产品的曲率超过某些值时，这种工艺可能不太有效。
美国专利No.5,025,895介绍了一种工艺，其中通过将若干粘合树脂用胶粘到各功能层上生产一种复合夹层。随后，将这种复合夹层进行热成形，并用来生产多层窗玻璃。然而，这些装置是复杂的，并且不能总是在减小曲率半径的情况下避免形成皱折。
美国专利No.5,264,058介绍了一种用于制造层压制品窗玻璃的工艺，其中在高温下将一层塑料层预成形，并且在不冷却的情况下，用来耦合玻璃薄板，同时使用上述玻璃薄板作为散热片来提取塑料层中的热量。随后将窗玻璃平板在高压釜中进行处理，以便得到最终产品。然而，这些装置也复杂，并且不能总是在减小曲率半径的情况下避免形成皱折。
欧洲专利申请EP 0,326,015A介绍了一种用于制造夹层的工艺，其中将功能薄膜进行热成形，而随后耦合到粘合树脂层上，以便粘附到玻璃薄板上，然而，在这种情况下，同样不能总是避免在减小曲率半径情况下的形成皱折。
最后，国际专利申请公报No.WO 91/19586公开了一种工艺，其中在所有终端层于一模具上热成形然后令其冷却的情况下，层压一种复合夹层。另外，终端产品不完全令人满意。
因此，从一个方面，本发明提供一种用于生产曲面层压玻璃板的工艺，所述层压玻璃板包括一个第一玻璃薄板和一个第二相应的玻璃薄板，所述第一和第二玻璃薄板与一夹层一起，该夹层包括至少一层双取向的热塑性功能层，亦即按照两个方向进行预拉伸，上述两个方向基本上在它们之间垂直，以便防止皱折，而相应的至少一层粘合树脂层由于夹层的折痕而具有减少的光学缺陷范围，这个工艺包括以下步骤：将上述夹层定位在两个玻璃薄板之间；及加压和加热以便形成一种多层板，所述多层板显示一种具有一个或多个曲率的终端形状，上述工艺其特征在于，将上述至少一层双取向热塑性功能层与上述至少一层粘合树脂一起在一模具上热成形成一种构造，所述构造基本上对应于上述曲面层压玻璃板的终端形状，然后在定位于上述玻璃薄板之间以形成上述夹层之前通过强制通风冷却。
在一个优选实施例中，夹层可以包括一层或多层功能层，所述功能层在热成形之前进行冷叠加，然后通过加热到一个足够所有功能层软化的温度，放在一个模具上，和在模具与夹层之间抽真空，接着通过强制通风最后冷却，在一个循环中进行热成形。
按照另一个优选实施例，功能层包括一个周边预切割部分，所述预切割部分易于从夹层中除去。在这个实施例中，将一个粘合树脂层粘附到上述功能层的一个表面上，随后将该功能层冷冲压成一种构造，所述构造基本上对应于上述曲面层压玻璃板的终端形状，放在一个模具上并加热，然后通过强制通风进行冷却。这个热成形步骤能使热塑性功能层在随后的用强制通风冷却之后永久定型。
将得到的夹层定位在一个玻璃薄板上，所述玻璃薄板把粘合树脂粘附到玻璃表面上，将上述预切割部分剥离，因而功能层的外部边缘保持距玻璃薄板边缘一定距离。然后，在将第二玻璃薄板定位在功能层上并加压和加热之前，在露出的功能层表面上加另一层粘合树脂层，以便形成显示具有一个或多个曲率的终端形状的多层窗玻璃。
本发明在生产曲面多层汽车窗用玻璃，尤其是挡风玻璃中找到特定的应用，上述挡风玻璃具有一高十字曲率度，比如说甚至超过20.0mm。它也可用于具有较小半径的窗用玻璃；比如，至少一个曲线具有半径为小于10,000.0mm，而在其表面上至少一个点处也许小于10.0mm。
本工艺能得到即使在其边缘处也没有任何光学缺陷的窗用玻璃，同时使周边暗淡带成为多余。
下面参照附图说明本发明的两个实施例，所述实施例作为例子而不是用于限制性目的，其中：
图1是按照本发明一个实施例所述工艺构成的挡风玻璃示意部件分解图；
图2示意示出按照本发明一个实施例所述工艺中所用功能薄膜的组成；
图3示出按照本发明一个实施例所述工艺的步骤；
图4示出按照本发明所述工艺的另一个步骤；以及
图5是按照本发明第二实施例所述工艺构成的挡风玻璃示意部件分解图。
参见图1-4，用于生产一种曲面层压玻璃板的本发明工艺具有提供一种玻璃板1的目的，所述玻璃板1包括一对成形的玻璃薄板2，并显示具有一个或多个曲率的形状。
在玻璃薄板之间，如上所述，插入一个夹层3，所述夹层3实施双重任务。实际上，按照这个实施例所述的夹层3包括3层：尤其是，两层粘合树脂层4和一层功能层5，上述两层粘合树脂层4定位成与上述玻璃薄板2接触，以便提供使它们保持接合所需的胶粘剂粘合强度。
上述粘合树脂优选的是聚乙烯醇缩丁醛(PVB)。
对于功能层，意思是指实施预定功能的一层，比如，一种具有特殊光学性能的滤光器，以便减少横过玻璃板的辐射太阳能，一种彩色层以便使玻璃板着色，一种局部反射层，一种预先安排用于玻璃电热加热的导电层。
具有很小厚度的聚对苯二甲酸乙二醇酯(PET)薄膜提供对功能层的足够支承。另一些足够的支承由其它热塑性树脂形成。
在材料具有热收缩性能情况下，如在PET情况下，用于功能层的薄膜有利的是双取向，亦即它按照两个基本上在它们之间垂直的坐标轴伸展。
在这个实施例(图2)中，所选定的功能层包括一种PET薄膜，所述PET薄膜用标号6表示，它具有各种不同性能的分层，所述各种不同性能的分层沉积在PET的一个表面上。尤其是，沉积了三层金属氧化物滤光分层7和交替式在三层之间的两层银反射分层8。
然而，应该理解，在粘合树脂中的性能分层数，功能层数及玻璃薄板数都可以改变，以便满足各种可能的需要。
按照这个实施例所述的工艺包括热成形夹层3，亦即粘合树脂层4和功能层5。
上述各层适当地预先层压并卷绕在收卷机的卷筒11上。将它们开卷并插在一个顶部压制件12和一个底部压制件13之间，上述底部压制件13定位在一个曲面模具14上方(图3)。
通过一个按扣紧固系统将薄膜紧固到压制件12，13上，经受冲孔的边缘将具有15-20mm的厚度。
在这个阶段，将封闭在压制件12，13之间的层4，5从模具中取出并经受加热，比方说通过带红外灯的辐射板加热系统进行加热。
加热温度设定在130℃±30℃下。
温度检测系统有利的是用一种红外高温计16操作，上述红外高温计具有一个通常是上述塑料波长的传感器，上述传感器检测薄膜叠层的温度升高情况。一旦温度达到预设的值，则电指令信号就启动一个中断加热的系统，亦即从薄膜中收回加热板。
按照一个优选方案，在加热期间，从底部喷射一股热空气射流，以便在薄膜定位在模具上之前实施薄膜预张紧。
然后，在吹气时间为1-3秒钟之后，模具将底部压制件升起到顶部压制件，或是将顶部压制件下放到底部压制件，同时迫使通过两个压制件12，13保持固定的层采取上述模具的形状。所有这些热成形步骤都是在真空下进行，因而进一步促进形成由上述薄膜叠加所产生的层(图4)。
在通过应用真空压制若干秒之后，启动一股冷空气射流，所述冷空气射流将上述层冷却到约30-40℃的温度，同时使功能层5的形状冻结，并因此使粘合树脂层4的形状冻结。
在通过强制通风操作的这种冷却之后，将使夹层3沿着所有这些步骤保持固定的两个压制件12，13重新打开，并且操作者可以回收经过成形的夹层3，为了更好的保持压制的形状特点，可以将上述夹层3堆装在一个支承件上，所述支承件具有与热成形所用模具相同的形状。
功能层5和各粘合树脂层4的热成形叠加可以用来按照常用的技术制造曲面玻璃板，上述曲面玻璃板还具有应用很小曲率半径的选择方案。
因此，按照这个实施例所述的工艺还包括在一合适的高压釜中将上述夹层3定位在两个玻璃薄板2之间的步骤，其中施加合适的压力和热量，以便形成一种层压玻璃板，所述层压玻璃板其特征在于终端形状具有一个或多个曲率。
这个步骤由于各粘合树脂层4粘附到相应的窗玻璃表面上而实现各玻璃薄板之间的接合。
夹层3的周围边缘未显示出皱折或折痕，因此上述夹层3的周围边缘可能不需要用压印在外部窗用玻璃(亦即，在建筑工地的汽车中，打算把窗玻璃放在外侧处)内表面上或者在内部玻璃窗(亦即，在建筑工地的汽车中，打算把窗玻璃放在内侧处)的内表面上的有点区掩蔽。
下面说明用于制造层压玻璃板的本工艺第二实施例，上述层压玻璃板包括一层透明的功能薄膜，所述功能薄膜埋置在各层压的层之间。
按照这个实施例，夹层3′由一层如上所述的功能层5，及由一层粘合到功能层一个表面上的粘合树脂层组成。
沿着功能层的整个边缘，功能层包括一个预先切割的周边部分5′(图5)，上述周边部分5′往往是在本工艺的随后步骤中除去。
在上述实施例的热成形步骤和冷却步骤之前，将夹层3′进行冷冲压，亦即在室温下进行预成形。这个冷冲压步骤包括双取向的热塑性功能层5和相应的粘合树脂层，它们成形为一种构造，所述构造基本上与待制造的曲面层压玻璃板的终端形状相对应。
对热成形步骤来说，对夹层3′抽真空，以使夹层3′粘附到一个合适的模具上，所述模具具有基本上与待制造的曲面层压玻璃板终端形状相对应的形状。夹层3′与完全粘附到模具表面上的功能层5一起定位。
通过合适的加热机构，将夹层3′加热到功能层热塑性材料的软化温度，亦即加热到130℃±30℃的温度。
加热阶段可以通过一种带红外灯的辐射板加热系统进行，所述辐射板加热系统具有一个使用红外高温计16的温度检测系统，所述温度检测系统具有一个通常是上述热塑性材料波长的传感器，上述传感器检测薄膜叠层的温度升高情况。一旦温度达到预设值，则电指令信号就启动一个使加热中断的系统，亦即从薄膜中收回加热板。
在若干秒种之后，启动一股冷空气射流，所述冷空气射流将上述各层冷却至约30-40℃的温度，同时使功能层的形状冻结。这样，通过用强制通风冷却，使双取向的热塑性功能层5永久定型。
在上述热成形步骤和冷却步骤之后，将夹层3′定位在一个玻璃薄板上方，所述玻璃薄板预定是一种内部窗用玻璃，亦即预定放置在最终玻璃板内侧处。将粘合树脂层4加到玻璃表面上。
在这个阶段，将上述预先切割的部分5′剥离，因而功能层5的外部边缘保持距接收窗用玻璃的边缘一定距离。
然后，至少在露出的功能层5表面上施加另一个粘合树脂层4，并将一个第二玻璃薄板定位于其上，所述第二玻璃薄板的形状完全与第一玻璃薄板和覆盖上述附加粘合树脂层4的夹层3′的形状匹配。
在这方面，按照本发明所述的复合玻璃板达到它的最终组成(图5)。现在将这种半成品放在合适的用于加压和加热的机构(比如高压釜)中，以便形成一种显示具有一个或多个曲率的终端形状的层压玻璃窗。
按照第二实施例，功能层5靠近边缘显示一种线性边缘，所述线性边缘几乎是可以理解的，并且可以很容易通过压印在内窗用玻璃内表面上的周边虚线区遮掩。这种构造比压印在外窗用玻璃内表面上的周边虚线区更容易得到。
此外，因为功能层保持距最终玻璃板的外部边缘有一定距离，所以能有效地防止由于在其边缘处窗用玻璃之间渗入大气介质或类似物而引起的腐蚀。
对于上述工艺，该技术的技术人员为了满足另一些可能的需要而可以实施一些进一步的改进和变动，然而所有的改进和变动都包括在如所附权利要求书所述的本发明保护范围内。

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1.一种用于生产曲面层压玻璃板(1)的工艺，所述曲面层压玻璃板(1)包括一个第一玻璃薄板和一个第二玻璃薄板(2)，上述第一和第二玻璃薄板(2)与一个夹层(3；3″)在一起，所述夹层(3；3″)包括至少一层双取向的热塑性功能层(5)和至少一层粘合树脂层(4)，这种工艺包括以下步骤：在一个模具上将上述至少一层双取向的热塑性功能层(5)与至少一层粘合树脂层(4)一起热成形，上述粘合树脂层(4)粘附到上述至少一层双取向的热塑性功能层(5)上，成一种基本上与上述曲面层压玻璃板(1)终端形状相对应的构造；通过强制通风将上述至少一层功能层(5)和上述合适的粘合树脂层(4)冷却，因而使上述至少一层功能层(5)的形状冻结；及将上述夹层(3；3″)定位在两个玻璃薄板(2)之间并加压和加热，以便形成一种具有一个或多个曲率的终端形状的多层窗用玻璃。
2.按照权利要求1所述的工艺，其特征在于，在热成形步骤期间，从底部喷射一股热空气射流，以便实施预张紧上述至少一层功能层(5)。
3.按照权利要求1-2其中之一所述的工艺，其特征在于，上述夹层(3)包括两个粘合树脂层(4)，所述两个粘合树脂层(4)预定定位到与不同的玻璃薄板(2)接触，每个粘合树脂层都粘附到一层功能层(5)的相对边上。
4.按照权利要求1所述的工艺，其特征在于，上述夹层(3′)包括一层功能层(5)，和相应的一层粘合树脂层(4)，所述粘合树脂层(4)粘附到功能层(5)的一个表面上，功能层(5)包括沿着其整个边缘的一个预先切割的周边部分(5′)，所述预先切割的周边部分(5′)往往会在随后的步骤中除去。
5.按照权利要求1或者4所述的工艺，其特征在于，在热成形步骤和冷却步骤之前，将上述夹层(3′)冷冲压成一种构造，所述构造基本上与待制造的曲面层压玻璃板的终端形状相对应。
6.按照权利要求4或5所述的工艺，其特征在于，在热成形步骤中，将夹层(3′)抽真空，以使它与粘附到模具表面上的功能层(5)一起粘合到模具上。
7.按照权利要求4-6其中之一所述的工艺，其特征在于，在定位步骤中，将成形的夹层(3′)定位在一个玻璃薄板(2)上，同时将一层粘合树脂层(4)加到玻璃表面上。
8.按照权利要求7所述的工艺，其特征在于，上述一个玻璃薄板(2)预定是在最终玻璃板(1)的内侧处。
9.按照权利要求7或8所述的工艺，其特征在于，当夹层(3′)已定位在上述一个玻璃薄板(2)上时，将上述预先切割的部分(5′)剥离，因而功能层(5)的外边缘保持距上述一个玻璃薄板(2)的边缘一定距离。
10.按照权利要求7-9其中之一所述的工艺，其特征在于，在定位步骤中，将一层另外的粘合树脂层(4)至少加在露出的功能层(5)表面上，并将一第二玻璃薄板(2)定位在上述粘合树脂层(4)上，其形状与上述一个玻璃薄板(2)及夹层(3′)的形状匹配，上述夹层(3′)被上述附加的粘合树脂层(4)覆盖。
11.按照上述权利要求其中之一所述的工艺，其特征在于，上述粘合树脂是聚乙烯醇缩丁醛(PVB)。
12.按照权利要求1-4其中之一所述的工艺，其特征在于，玻璃板是一种具有十字曲率为至少5.0mm的曲面玻璃板。
13.按照权利要求1-4其中之一所述的工艺，其特征在于，玻璃板是一种曲面玻璃板，其中至少一部分曲面表面具有一半径为小于10000mm。
14.按照上述权利要求其中之一所述的工艺，其特征在于，上述功能层(5)包括一种聚对苯二甲酸乙二醇酯薄膜(6)，所述薄膜(6)具有一层或多层粘附于其上的滤光分层(7)和/或反射分层(8)。
15.按照上述权利要求其中之一所述的工艺，其特征在于，在热成形时，将加热温度设定在130℃±30℃处。
16.按照上述权利要求其中之一所述的工艺，其特征在于，在热成形时，应用了一个利用红外高温计(16)的温度检测系统，所述红外高温计(16)具有一波长传感器，所述波长传感器检测上述至少一层双取向热塑性功能薄膜(5)和上述合适粘合树脂层(4)的温度升高情况，一旦温度达到预设值，则启动一个使加热中断的系统。
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