CN1936073A - 一种为粘接目的涂覆基板的方法 - Google Patents
一种为粘接目的涂覆基板的方法 Download PDFInfo
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- CN1936073A CN1936073A CNA2006101530509A CN200610153050A CN1936073A CN 1936073 A CN1936073 A CN 1936073A CN A2006101530509 A CNA2006101530509 A CN A2006101530509A CN 200610153050 A CN200610153050 A CN 200610153050A CN 1936073 A CN1936073 A CN 1936073A
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Abstract
一种为粘接目的在玻璃基板上沉积涂层的方法。其工艺包括沉积涂层,在第一时间段里清洁表面,在第二时间段里用大气压空气等离子在大气压下在表面沉积高速冲击聚合物反应涂层。该涂覆玻璃可以用CASE化合物粘接,其包括:涂料、粘接剂、密封剂、弹性体及其结合。该CASE化合物的对立面接近框架,例如机动车挡风玻璃凸缘。
Description
技术领域
本发明的一个方面涉及一种为粘接目的涂覆基板的方法。
背景技术
在许多商品的生产中,常常需要连接不同的材料。很多时候,都必需对一种或两种材料的表面性质进行调整。在制造业中调整材料的表面性质常常包括表面处理技术。这些表面性质的部分例子包括:表面能、化学惰性、传导率、可染色性和可粘接性。使用表面处理与制备的应用的部分例子包括:在易腐蚀的金属如铁或钢上的防腐蚀涂层,在植入物上的生物相容性涂层,电子材料上的防水层以及玻璃上的粘接剂。
将涂料(Coatings)、粘接剂(Adhesives)、密封剂(Sealants)和弹性体(Elastomers)(以下简称CASE)涂覆于基板上,通常需要在对表面的处理和预处理中特别小心,以防止基板和所涂覆的CASE粘接失败。许多CASE的涂覆过程包括以下步骤:(a)清洁表面或表面粗糙化,(b)涂覆与表面粘接或对表面腐蚀的底漆,(c)涂覆增强剂以增加附加的粘接功能。CASE化合物应用于包括建筑、汽车、医药、牙科、标签、电子和包装等产业。
在汽车工业中,CASE化合物应用于玻璃装配工艺中。不利的是,汽车玻璃很容易会因边缘所受的机械震动而破坏。因此,边缘通常被封装起来。在一种封装方法中,用一个框架将玻璃与汽车上部结构连接起来。因此框架包住玻璃的边缘部分。在一种将玻璃和框架结合起来的方法中,用一种溶剂清洁该玻璃,在玻璃表面涂上一种含偶联剂的底漆,以化学方法改变其表面,最后,涂覆一层较厚的油漆似的化合物,紧紧地粘结在框架上。在该例子中,准确对齐两层涂层,即底漆层和油漆似的化合物层是很困难的,因为底漆在玻璃上干燥后会变得十分透明,但是第二层是不透明的,当其涂覆的宽度大于底漆的宽度时就无法准确地对齐。
当汽车玻璃用作挡风玻璃时,它用来阻挡物质和能量,例如:风、雨、碎屑、红外线热量进入车厢,同时在车辆碰撞和翻转时,通过增加结构的整体性保证乘客的安全。有时,汽车玻璃的表面是非一致的,它可能在某些部位含有熔体,用来遮蔽红外线、紫外线和其它波长的阳光。同样地,它可能在某些部位是带色的。还有,它上面可能有间隙,以便于紧固件的安装。在上第二层密封剂时,这些间隙可能需要费工夫地进行掩饰。
连接不同材料的其它方面包括希望提高制造的精确度、生产率、自动化程度、可靠性和/或可制造性,同时降低有害的副作用,原料的用量和/或能量和原料的浪费。例如,有些CASE化合物会有相当数量的浪费。耦联剂底漆往往只有不到1%的有效成份,而超过99%的是载体溶剂。在另一个例子中,清洁材料有有害的副作用,例如易燃的和/或有毒的溶剂如异丙醇或甲苯。在其它情况下,油漆似的涂层往往必须在30秒内在空气中干燥,所以使用了挥发性溶剂。驱散这些挥发物和保障工人的健康耗费了精力和金钱。
近来,开发出了等离子聚合,作为改变材料的表面性质,同时提高可制造性、自动化程度、制造的精确度,同时减少有害副作用以及原料和能量浪费的一种工具。
根据输出温度、压力情况、化学和热平衡状态,等离子体可以做不同的分类。例如,有在低于大气压条件下生产的等离子体。这样的例子包括典型地用在物理气相沉积中的由磁电管产生的包含高密度等离子体和低密度等离子体的等离子体。其它的大气压条件下的例子有:辉光放电,感应耦接和重组等离子体。辉光放电的特点是,气体几米每秒的低移动速率。它的特点是化学和热的不平衡。感应耦接等离子体的气体移动速率为中到低。它的特点是局部热平衡。重组氮或空气等离子体具有大约1000米/秒的高气体速率,其特点是化学平衡。等离子体分类的其它例子取决于它们的离子化方法,如微波谐振和电火花法。
当等离子体应用于实验室外的大批量生产时,可制造性和自动化程度的另外问题就出现了,如运转速度、与基板的兼容性和污染。
在很多应用中,等离子处理的发生很快,一般为若干纳秒到几分钟,它可以有效地取消如物理气相沉积等间隙真空技术。
高温等离子体会使基板燃烧或受到热冲击,特别是那些热传导系数小而熔点或燃点又低的基板。
另外,有些表面具有缺陷,如有灰尘,有机身体护理油和运输和操作中产生的碎屑。
考虑到上述情况,需要一种方法,以在制备表面以连接两种不同材料或接受CASE化合物的大批量生产工艺中提高制造的精确度、生产率、自动化程度、可靠性和/或可制造性,同时降低有害副作用、原料的用量和/或能量和材料的浪费。
发明内容
本发明的一个实施例为一种沉积涂层的方法,其中用大气压空气等离子(APAP)在第一时间段里清洁表面,在第二时间段里在大气压下在表面沉积一层高速冲击聚合物反应涂层。
本发明的另一个实施例为一种涂层的涂覆方法,其包括将一种预聚物蒸汽与载体气体或小滴薄雾混合,将该混合物引入大气压空气等离子以形成聚合物反应化合物,然后在大气压空气等离子的排出气体的高速冲击推动下涂覆该聚合体反应混合物。
本发明的再一实施例为涂覆的玻璃表面,具有在清洁之后用大气压空气等离子直接涂覆了高速冲击聚合物反应涂层的例如新的或旧的挡风玻璃表面。本实施例的另一方面包括具有例如为密封剂的第二层以连接不同材料,例如挡风玻璃和框架。本实施例的再一方面包括,用多条行进路径或多个在实质上顺序排列或平行的行进路径中行进的APAPs在表面上形成高速冲击聚合物反应涂层的复合沉积层。
附图说明
图1表示本发明的某些实施例应用于车辆的一个例子;
图2表示在本发明的某些实施例的表面沉积高速冲击聚合物反应涂层的一个例子;
图3表示在本发明的某些实施例的表面沉积高速冲击聚合物反应涂层的另一个例子;
图4表示本发明的某些实施例的具有高速冲击聚合物反应涂层、第二层和框架的涂覆玻璃表面的一个例子;
图5表示本发明的某些实施例的具有复合高速冲击聚合物反应涂层的涂覆玻璃表面的一个例子;
图6表示本发明的某些实施例的具有复合高速冲击聚合物反应涂层的涂覆玻璃表面的一个例子;
图7表示根据本发明的某些实施例的一个预聚物传输系统的一个例子;
图8表示一个雾化器束套的沿8-8线的横截面。
具体实施方式
以下将就发明人所知对本发明的化合物、实施例与方法作出详细说明。然而,应当知道所公开的实施例仅仅是本发明的示例,它们可以用不同的和可替换的方式实现。因此,这里所公开的具体细节不应理解为对本发明的限制,其只不过是向所属技术领域的技术人员传授本发明的各种使用方式的代表性的基本方式。
除非清楚地指明,此说明书中的所有表明材料的量或反应和/或使用条件的量都应被理解为在说明本发明的最宽泛的范围时,被“大约”一词所修饰。在所述的数字范围内的实施方式一般是较佳的。
关于适合本发明的一个特定目的的一组或一类材料的说明意味着该组或该类中的任何两个或更多个组分的混合也是适合的。对化学成分的说明是指添加到说明书中指明的任何组合时的成分,不一定排除混合后的混合物成分之间的化学相互作用。首写字母缩略词或其它缩略词的第一次定义将应用于所有后来用到的与此相同的缩略词,并准用于最初定义的缩略词的通常语法变化。除非有清楚的相反的说明,对之前或之后引用的同一特性的度量决定于相同的技术。
图1表示在机动车1上具有不同材料连接的区域,包括挡风玻璃8,侧窗9,天窗13,后窗和后视镜11。使用涂料、粘接剂、密封剂和弹性体的其它区域,包含但不限于金属表面,例如轮毂罩18,装饰用的弹性体压条14,车体内部件,天窗密封条12,引擎罩下的控制引擎的电路板16,塑料裙板20等可喷涂的和耐磨表面。
机动车的挡风玻璃系统可以包括一个装在汽车车体表面系统2的框架4,密封剂,底漆,以及玻璃表面。挡风玻璃8的玻璃表面可以包括熔块10和/或着色区6。其它例子的系统可以包括弹性体压条,涂覆于该压条的粘接剂,在引擎罩下的有防水涂层的组成部分或电路板,此板与车辆的电路系统相连接。
参照图2,在大气压空气等离子(APAP)系统中,在给料罐22中的预聚物形式的可聚合的材料通过管材30输送,经一个大流量控制器32计量,雾化,在混合室38中与载体气体混合。该载体气体从载体气体给料罐36通过计量器34引入混合室38中。该混合物被引入装有离子化气体的等离子体的大气压空气等离子装置44。该离子化气体通过一个计量器42来自离子化气体给料罐40。该空气等离子装置周围的室内气压的范围为大于50千帕、75千帕或100千帕而小于300千帕、250千帕、200千帕或150千帕。在出口喷嘴50处,高速聚合物反应涂层的速率可以达到大于10m/s、50m/s或75m/s而小于200m/s、150m/s或125m/s。从喷嘴50喷出的气体的温度小于450℃、400℃、350℃、325℃或300℃而大于70℃、100℃、125℃或150℃;同时基板的温度可以低于95℃、85℃、75℃、70℃、65℃、60℃、55℃或50℃,取决于操作条件。该基板的温度使该工艺在易受热损害的基板上进行。
从出口喷嘴50喷出的气体形成喷射式样,其外半影56主要是用来清洁和/或活化的离子化气体。靠近喷射式样的中心的是高速冲击聚合物反应涂覆材料的高浓度区域54。接受高速冲击聚合物反应涂覆62的表面58是机动车的具有陶瓷熔体60和着色玻璃64的挡风玻璃28。该挡风玻璃装在框架66中。
接受涂层的表面可能会因电离作用和热而活性化,可能是清洁的、被碎屑覆盖的或是被腐蚀的。该表面可以用大气压空气等离子清洁和部分的活性化。大气压空气等离子的可能的清洁和活性化机制本身可能包括对风化玻璃的负碱性层的修理,使表面离子化,改变表面能,燃烧油脂和灰尘或其结合。当该大气压空气等离子在本发明的一个实施例中同时作为高速冲击聚合物涂覆手段时,从喷嘴喷出的大气压空气等离子的半影可具有电离作用和热产生的清洁功能。因此,在本实施例中,清洁和/或活性化步骤和沉淀步骤的间隔时间大于1μs、5μs、10μs、25μs或100μs。
本发明的另一个实施例包括有一个或多个单独的大气压空气等离子体以清洁和/或活化表面,接下来又有一个或多个单独的大气压空气等离子体沉积高速冲击聚合物涂层。这些APAPs可以按顺序操作,平行操作或结合起来操作。当多个APAPs作为一组平行使用时,通常其间距可以为约2mm。
清洁和/或活性化操作可以比沉积操作或清洁和/或活性化和沉积的结合操作使用更快的移动速度。这些实施例的其它方面可以包括,在作清洁操作时使用宽径出口,而且沉积操作中使用光栅式出口。清洁和/或活性化操作可以通过其它的如电晕放电或燃烧源等离子化技术完成。根据本实施例,清洁/活性化步骤和沉积步骤的间隔时间大于0.1秒(s)、1s、5s、10s、25s或100s而小于150s、300s、10分钟(min)、30min、1小时(hr)、12hr、1天、2天或5天。
本发明的另一个实施例能够使预聚物有梯度,其中另一个装有其他预聚物的给料罐24通过输送管26连接到预聚物给料罐22以增量调整在给料罐中的预聚物的比例。本实施例的另一方面是让其它预聚物通过给料管28输入到可以根据预聚物的比例对增加或递减进行调整的计量器32。
在某些实施例中,APAP可以给表面涂层引入等离子空气处理以活化表面涂层。例如,表面可以在一个部位进行清洁和涂覆,然后移到另外一个部位以在以后进行活化。
参照图3,在本发明的一个实施例中,表面68有一个由高速冲击聚合物反应涂层70和由另一个步骤形成的CASE化合物72组成的复合层,以将表面68的不同材料和框架74的部分相连接。该CASE化合物在后续的高速冲击聚合物反应涂层的光栅沉积中由APAP 78的光辐射76在附近经过时予以固化。
参照图4,在本发明的另一个实施例中,形成复合层以保护电路板80及其焊片86使其防水、其它液体和蒸气。涂覆高速冲击聚合物反应涂层82使得电路板80和焊片86可以与另外一层具有防水性能的高速冲击聚合物反应涂层84相粘接。
参照图5,本发明的另一个实施例表示了光栅复合沉积。在该实施例中,表面88用一种预聚物形成的APAP高速冲击聚合物反应涂层90进行处理。第二沉积层92与第一层平行,是从第一层平移过来的。第二沉积层92可用经独立选择的预聚物产生APAP高速冲击聚合物反应涂层。
参照图6,本发明的另一个实施例表示了多层复合沉积。在本实施例中,表面94上涂上一层APAP高速冲击聚合物反应涂层。在一条路径上形成不平衡的复合层。第一层102是从给料罐中提供的100%的第一预聚物形成的高速冲击聚合物反应涂层。第二层104是从给料罐中提供的第一预聚物和第二预聚物的混合物形成的高速冲击聚合物反应涂层。第三层106是从给料罐中提供的100%的第二预聚物形成的高速冲击聚合物反应涂层。此时的表面性质已被改变以适应任何的后续的涂层,这在图中未示出,以提供保护性涂层和/或表面性质,如同具有化学和生物防护功能的织物表面,或为基础的APAP高速率冲击聚合反应涂层提供更耐久的保护涂层。
参照图7和图8,其表示了一个预聚物传输系统,其中离子化气体由管112供给APAP 114,其具有装有雾化束套118的出口喷嘴116,其促使预聚物薄雾128进入高速冲击聚合物反应涂层材料122中。预聚物材料供给注射器132,其将该材料注入到雾化束套118的喷雾嘴133以产生预聚物薄雾128。高速冲击聚合物反应涂层材料122被喷涂于表面126上,作为高速冲击聚合物反应涂层124。
可以进行活化和沉积的表面可以包括但不限于:玻璃质材料、多层挡风玻璃、车辆玻璃、玻璃、溶蚀玻璃、含有熔体的玻璃、着色玻璃、硅酸盐、铝酸盐、硼酸盐、氧化锆、过度金属化合物、钢、碳酸盐、生物相容性材料、磷酸钙矿物、磷酸四钙、磷酸二钙、磷酸三钙、磷酸二氢钙、磷酸二氢钙一水合物、羟磷灰石、层压电路板、环氧树脂、木材、纺织品、天然纤维、热塑性塑料、热固性塑料、熔融温度大于70℃的表面、含对热损伤敏感的成分的表面或其结合。在含熔体的和着色的玻璃中,熔体和着色剂可能在表面、分散在表面或两者都有。含热敏感成分的表面可能含有熔点或再结晶温度小于400℃、350℃、300℃、250℃、200℃、150℃、100℃或小于100℃的成分。一个易受热破坏的表面的其它指标可能包括工作温度小于350℃、300℃、250℃、200℃、150℃、100℃或小于50℃,或材料的玻璃转换温度小于200℃、150℃、100℃或小于50℃。
如果表面或沉积层的线性热膨胀系数大于10×10-6/℃、15×10-6/℃、20×10-6/℃或50×10-6/℃,这样的表面也应当被认为是对被热损伤敏感的表面。表面和APAP沉积层的不同的膨胀率可能导致因剪应力而产生尺寸错变或破坏。如果表面的化学分解温度小于400℃、350℃、300℃、250℃或小于250℃,这样的表面也应当被认为是对热损伤敏感的表面。分解可以被认为是一种反应的例子,在该反应中材料或表面材料的粘接化学裂开。可以发生裂化的其它的化学反应的例子包括:燃烧、脱水、去碳酸基、高温分解和氧化。
对热损伤敏感的表面包括制造铸型和冲模的原型和需要修理和保护涂层的表面。另外,表面和所涂覆的熔化材料之间的热膨胀的不同可能引起部件或固化的APAP涂覆材料的残余应力。弯曲的部件会因热冲击而破裂。对热损伤敏感的表面的材料成分的例子包括:环氧树脂工具、硅树脂模具、加工板、雕塑板、泡沫板、中密度纤维板、纤维层压板、成形板材、可加工石蜡、薄壳工具和各种快速成型材料,例如:激光固化树脂、层压纸板、石蜡、木材、泡沫聚合物、烧结陶瓷。
对热损伤敏感的表面也可以是有很小的散余热面积的薄壳体。一个典型的薄壳体的厚度可能小于25mm、20mm、15mm、10mm、5mm、4mm、3mm、2mm甚至小于1mm。
对热损伤敏感的表面也可以是存有大量残余应力的材料。当暴露于大于50℃、100℃、150℃或200℃而小于400℃、350℃、300℃或250℃的温度时,这些残余应力会全部或部分释放。其结果可能引起对热损伤敏感的表面的尺寸变形或扭曲。
离子聚合产生的不是常规的化学条件下的一般聚合物排列。该聚合物可能有多支链、随机断链或官能团交联点。一般地,缺乏规则的重复单元。这是它们暴露在等离子固有的高能量电子中预聚物分子发生断裂的结果。这种反应似乎是通过多种反应方式进行的,包括:自由基形成、均裂、阳离子寡聚及其结合。
大气压空气等离子反应的沉积结果不同于常规的聚合物、低聚物和单体。在常规的单体、低聚物和聚合物中有一标准系列的一个或多个最小组成单元或者叫作链节。随着聚合物链的增长,最小组成单元也重复并偶尔地交叉连接。在等离子聚合物中,最小组成单元可能断裂而产生新的官能团。在它们重组时,它们可能具有高交联密度,出现更多的支链、随机断链或它们的结合。由于交叉链的数量除以主链分子的数量趋于一致,计算交联密度变得更加困难。等离子聚合物就可能是这种情况。与交联密度相关的量度可以是玻璃转换温度相对于常规聚合物的不同。可以认为,在交联程度较低的情况下,超出转换温度就相当于交联的数量。在等离子聚合物中,相对于常规的聚合物,分布的坡度可能相应的增加10%、15%或20%。
适合用大气压空气等离子沉积的预聚物包括能蒸发的化合物。该蒸气可以与载体气体一起度量和混合。该气体混合物可以引入由大气压空气等离子产生的等离子。大气压空气等离子的离子化气体可以从典型的焊接气体中选择,其包括但不限于:惰性气体、氧气、氮气、氢气、二氧化碳及其结合。
用来产生高速冲击聚合物涂层的预聚物包括的不限于,例如符合公式RaX(3-a)M1-O-M2RbX(3-b)的第14组活性替代化合物,其中R为具有能赋予所需特征的功能的可水解的有机基,X可以是卤素,M为例如硅的第14组元素,O为氧;那些符合公式RnMX(4-n)的化合物,其中R可以是易水解的有机基,M为例如硅的第14组元素,X可以是卤素;那些符合公式R2MO的化合物,其中R为可水解的有机基,M为的第14组元素,O为氧;直链型硅氧烷;循环的硅氧烷;甲基丙烯基硅烷化合物;苯乙烯基官能硅烷化合物;烷氧基硅烷化合物;酰氧基硅烷化合物;氨基替代硅烷化合物;六甲基二硅氧烷;四乙氧基硅烷;八甲基三硅氧烷;六甲基环三硅氧烷;八甲基环四二硅氧烷;四甲基硅烷;乙烯基甲基硅烷;乙烯基三乙氧基硅烷;乙烯基三(甲氧基乙氧基)硅烷;氨基丙基三乙氧基硅烷;甲基丙烯酰氧丙基三甲氧基硅烷;缩水甘油醚基丙基三甲氧基硅;六甲基二硅氮烷和硅、氢、碳、氧或氮原子的分子间结合;有机硅烷卤化物;有机锗烷卤化物;有机锡卤化物;钕镨[对(三甲基硅烷基)甲基]锗;钕镨[对(三甲基硅烷基)氨基]锗;铝或钛的有机金属化合物及其结合。它们还可以包括压缩在气筒中的或低温下液化的或在提高温度时受控蒸发的气体。
在某些实施例中,高速冲击聚合物涂层的厚度可以增加到足以在部分的框架上产生密封。厚度的积累可以由增加允许范围内的沉积时间、增加沉积量、增加沉积体积,或其结合来完成。增加沉积时间包括但不限于增加APAP在同一位置沉积的时间或用多个APAPS作用于同一部位。
在本发明的另一个实施例中,多个APAPs可以沉积不同的预聚物,以产生一个复合的沉积层,不同的预聚物在不同的空间区域产生光栅复合沉积,或其结合。
本发明的又一个实施例涉及用APAP涂覆预聚物作为底漆。然后可以将第二层涂覆到底漆上以将底漆和一部分框架连接起来。在非限定性的例子中,第二层将一块挡风玻璃与框架连接起来,高速冲击聚合物涂层的宽度可以是10mm。第二层的宽度典型的为等于或宽于高速冲击聚合物涂层的宽度。第二层可以包括但不限于:CASE化合物、聚亚安酯化合物、聚酰亚胺化合物、金属涂层、聚酰胺化合物、清漆、硫化材料、有机薄膜、抗腐蚀化合物、生物相容性涂层、憎水化合物、亲水化合物、硅氧烷化合物、锡、锗、陶瓷釉料、油漆、环氧树脂及其结合。CASE化合物包括但不限于:保护涂层、耐磨涂层、防腐涂层、油漆、保形涂层、环氧保护涂层、丙烯酸保护涂层、醇酸树脂保护涂层、聚亚安酯保护涂层、压力敏感粘接剂、乳液聚合体、硅树脂、木材防腐剂、热塑性橡胶、医用粘接剂、织物涂层、堵缝剂、橡胶、粉沫涂层、黑烟末、辐射熟化物质及其结合。
对第二层的黏着可以采用快刀分析法(Quick Knife Analysis method)进行分析。依照该方法,在对表面进行处理后,CASE化合物的微粒被涂覆到表面,然后经三天时间的干燥。三天之后,用刀片将它们对角地割开。然后将这些部分弯曲和拉扯,直到它们彼此间不再粘接或内聚或其结合。破坏的模式被记录下来。
框架可以用来保护或将一部分或几部分不同的材料连接到表面系统结构上。框架可以由符合设计目的任何数目的材料构成。具体例子包括但不限于:金属沟槽或汽车玻璃四周的聚亚安酯罩或具有防水涂层的电路板的焊片。
例1
APAP清洁和活化步骤和高速冲击聚合物反应涂层沉积发生在一个步骤中。我们不想局限于单独的操作理论,看起来好像是在第一时间段里,从喷嘴喷出的APAP气体有一个离子化等离子体的半影完成清洁和活化步骤,也可以简称为清洗,紧接着在同一步骤中的集中到从喷嘴喷出的离子化等离子体中心位置的高速冲击聚合物反应涂层沉积。
在本例中,由装有由等离子处理北美公司(Plasma Treat North America,Inc.)提供的APAP流动槽(FLUME APAP)的机械手传送由六甲基二硅氧烷(HMDSO)的预聚物生成的高速冲击聚合物反应涂料。大约30g每小时的HMDSO稀释于5L每分钟的空气中。HMDSO和空气的混合物输送到APAP。该离子化气体以30L每分钟导入。高速冲击聚合物反应涂料从一个距离玻璃表面8mm的出口喷嘴涂覆到玻璃上,机械手在需要转向时,例如在间距为2mm的光栅式样中,其移动速率达到600mm每秒。
例2
在本例中,清洁和活化步骤独立于高速冲击聚合物反应涂层沉积步骤。在机械手上的APAP以25mm每秒速度跟踪机械手气体。用与例1相同的条件。
在本例中,由装有由等离子处理北美公司提供的APAP流动槽的机械手使等离子体通过表面以清洁表面。离子化气体、空气以30L每分钟的速率导入。清洁用等离子体从距离玻璃表面8mm、轨迹间距为2mm的出口喷嘴喷到玻璃上,机械手在需要转向时,例如在间距为2mm的光栅式样中,其移动速率达到600mm每秒。第二APAP和该清洁用等离子体具有相同的机械手行进路径,输送四乙氧基二硅氧烷(TES)预聚物生成的高速冲击聚合物反应涂料。大约30g每小时的TES稀释于5L每分钟的空气中。TES和空气的混合物输送到APAP。该离子化气体以30L每分钟的速率导入。高速冲击聚合物反应涂料从一个距离玻璃表面8mm的出口喷嘴涂覆到玻璃上,机械手在需要转向时,例如在间距为2mm的光栅式样中,其移动速率达到600mm每秒。
例3
本例表示清洁表面然后沉积高速冲击聚合物反应涂层在一个或两个步骤中用一个APAP完成与只用一个APAP清洁和活化玻璃,以及用异丙醇溶剂擦洗玻璃,或直接将预聚物喷到玻璃表面相比,可以提高第二层与玻璃的粘接。
表示粘接结果的测试方法是快刀附着力方法(Quick Knife Adhesionmethod)。处理之后,CASE化合物微粒,在本例中为聚亚安酯密封剂,被涂覆到表面,然后干燥3天时间。三天之后,用刀片将它们对角地割开。然后将这些部分弯曲和拉扯,直到微粒粘接破坏或内聚破坏。希望得到的结果是内聚破坏。
适用的表面包括:标准的机动车挡风玻璃,已暴露在空气中一年的脏的挡风玻璃形式的被腐蚀的机动车玻璃,含有一个熔体区的挡风玻璃。
检测的结果记录在表1中。
表1
被腐蚀的玻璃 | 烧结玻璃 | 挡风玻璃 | |
无处理 | 粘接破坏 | 粘接破坏 | 粘接破坏 |
只用HMDSO | 粘接破坏 | 70%粘接破坏;30%内聚破坏 | 95%粘接破坏;5%内聚破坏 |
只用APAP | 内聚破坏 | 粘接破坏 | 内聚破坏 |
异丙醇溶剂擦涂 | 粘接破坏 | 粘接破坏 | 粘接破坏 |
APAP和HMDSO同一步骤 | 粘接破坏 | 内聚破坏 | 内聚破坏 |
APAP和HMDSO两个步骤 | 内聚破坏 | 内聚破坏 | 内聚破坏 |
另外,含有熔体并暴露于同样的腐蚀条件下的被腐蚀的玻璃只有在同样的沉积条件下的两步骤操作中才显示出内聚破坏。
例4
本例表示多层复合高速冲击聚合物反应涂层的创建。涂覆条件同例2中的条件相似。
在本例中,一个单独的APAP清洁和活化表面。机械手上的第二个APAP用HMDSO作为预聚物涂覆一层0.1μm的高速冲击聚合物反应涂层。机械手上的第三个APAP跟踪与第二个APAP相同的机械手的路径用八甲基三硅氧烷的预聚物涂覆一层0.05μm的高速冲击聚合物反应涂层。
例5
本例表示光栅复合高速冲击聚合物反应涂层的创建。涂覆条件与例2中的条件相似。
在本例中,一个单独的APAP清洁和活化表面。机械手上的第二个APAP用HMDSO作为预聚物涂覆一层0.1μm的高速冲击聚合物反应涂层。机械手上的第三个APAP跟踪平行于从第二个APAP平移2mm的机械手路径,并用八甲基三硅氧烷作为预聚物涂覆一层0.1μm的高速冲击聚合物反应涂层。
例6
本例表示分级的高速冲击聚合物反应涂层的创建。涂覆条件与例2中的条件相似。
在本例中,一个单独的APAP清洁和活化表面。机械手上的第二个APAP涂覆一层0.1μm的高速冲击聚合物反应涂层。开始的预聚物为纯的HMDSO的预聚物。当第二机械手路径经过与第一个路径相同的路径时,第二个APAP用调整到HMDSO和八甲基三硅氧烷的体积相同的预聚物混合物。当第三机械手路径经过与第一个路径相同的路径时,第二个APAP用调整为纯的八甲基三硅氧烷的预聚物。
例7
在本例中,表示了利用可中断高速冲击聚合物反应涂层和/或清洁和活化步骤的能力以在表面生成一个掩膜的实施例。涂覆条件与例2中的条件相似。
在本例中,一个单独的机械手上的APAP清洁和活化表面,于0.01秒内沉积1μm的高速冲击聚合物反应涂层。使用一个预设程序信号,该APAP关闭生成等离子体和预聚物流的离子化进程。该机械手继续行进一段距离。使用第二个预设程序信号,该APAP恢复清洁和活化步骤和高速冲击聚合物反应涂层沉积。
0.5秒之后,另一个机械手沿着该APAP走过的相同的机械手行进路径涂覆一层辐射熟化处理的CASE密封剂。该APAP发出的红外光和/或紫外光使该CASE密封剂固化。
在后继的操作中,一个锋利的工具沿着高速冲击聚合物反应涂层和未涂覆区域的分界将该CASE密封剂割开。未涂覆区域的CASE密封剂于是被完全从表面移去,因为它粘接失败。
例8
本例表示对等离子体的操作条件对高速冲击聚合物反应涂层的成分的影响。在一个有等离子室的物理气相沉积系统中,将其抽空到0.027Pa的压力,,由40kg赫兹磁电管生成等离子体,注入HMDSO的预聚物。生成的聚合物反应涂层的化学分析表明硅含量为19.8的原子百分比(atompercent)(at%)。
使用例2的条件,当HMDSO预聚物注入时,对生成的高速冲击聚合物反应涂层进行分析表明有32.0at%的硅含量。使用此技术的涂层的硅含量可望在25at%以上。
例9
本例描述了使用不同参数的涂覆速度时表面达到的温度。当出口喷嘴与表面距离为8mm,机械手的移动速率为600mm/s时,表面温度最高可达95℃。当机械手的移动速率为50mm/s时,表面温度最高可达180℃。
虽然实施本发明的最佳方式已详细说明如上,然所属技术领域的技术人员当可认识到为实施本发明的各种变更设计和具体实施方式仍在本发明的权利要求限定之内。
Claims (20)
1.一种为粘接目的涂覆表面的方法,其特征是该方法包括:
(a)在第一时间段里清洁表面;以及
(b)在第二时间段里在大气压下在表面沉积高速冲击聚合物反应涂层。
2.根据权利要求1所述的方法,其特征是进一步包括,(c)在步骤(a)和步骤(b)之间等候一个第三时间段,该第三时间段大于0.001秒小于5天。
3.根据权利要求1所述的方法,其特征是进一步包括,(c)在涂覆的表面粘着地涂覆第二层。
4.根据权利要求1所述的方法,其特征是进一步包括,(c)用等离子空气处理活化表面。
5.根据权利要求3所述的方法,其特征是该第二层为从涂料、粘接剂、密封剂、弹性体化合物及其结合中选择出的材料。
6.根据权利要求1所述的方法,其特征是该待粘接的表面为玻璃材料或涂覆陶瓷釉料的玻璃材料。
7.根据权利要求1所述的方法,其特征是喷嘴的沉积速率大于10m/s小于200m/s。
8.根据权利要求1所述的方法,其特征是该涂层由一种活性替代硅基预聚物构成,其硅原子含量最少为25%。
9.一种为粘接目的涂覆表面的方法,其特征是该法方法包括:
(a)将预聚物蒸气引入大气压力空气等离子以形成聚合物反应化合物;以及
(b)用高速冲击装置沉积该聚合物反应化合物。
10.根据权利要求9所述的方法,其特征是在步骤(a)中包括以薄雾状引入预聚物。
11.根据权利要求9所述的方法,其特征是该预聚物为符合公式RaX(3-a)M1-O-M2RbX(3-b)的第14组活性替代化合物,其中R为可水解的有机基,X为卤素,M为例如硅的第14组元素,O为氧;或者为符合公式RnMX(4-n)的化合物,其中R为易水解的有机基,M为例如硅的第14组元素,X是卤素,例如四乙氧基硅烷。
12.根据权利要求11所述的方法,其特征是该活性替代化合物为六甲基二硅氧烷。
13.一涂覆玻璃表面,其特征是该表面包括:
(a)玻璃表面;以及
(b)高速冲击聚合物反应涂层有第一和第二对立面,该第一对立面接近玻璃表面。
14.根据权利要求13所述的涂覆玻璃表面,其特征是其进一步包括(c)接近高速冲击聚合物反应涂层第二对立面一部分的框架。
15.根据权利要求14所述的涂覆玻璃表面,其特征是其进一步包括:(c)含有第三和第四对立面的第二层,其中该第三对立面接近高速冲击聚合物反应涂层的第二对立面,该第四对立面接近框架的一部分。
16.根据权利要求15所述的涂覆玻璃表面,其特征是该第二层为从涂料、粘接剂、密封剂、弹性体化合物及其结合中选择出的材料。
17.根据权利要求13所述的涂覆玻璃表面,其特征是该高速冲击聚合物反应涂层由预聚物蒸汽的大气压空气等离子沉积涂覆。
18.根据权利要求17所述的涂覆玻璃表面,其特征是该预聚物为符合公式RaX(3-a)M1-O-M2RbX(3-b)的第14组活性替代化合物,其中R为可水解的有机基,X为卤素,M为例如硅的第14组元素,O为氧;或者为符合公式RnMX(4-n)的化合物,其中R为易水解的有机基,M为例如硅的第14组元素,X是卤素,例如四乙氧基硅烷。
19.根据权利要求13所述的涂覆玻璃表面,其特征是该玻璃表面为机动车玻璃表面。
20.根据权利要求13所述的涂覆玻璃表面,其特征是该涂层为复合涂层。
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- 2006-09-06 CA CA2559293A patent/CA2559293C/en not_active Expired - Fee Related
- 2006-09-06 TW TW95132893A patent/TWI410389B/zh not_active IP Right Cessation
- 2006-09-18 DE DE200610044347 patent/DE102006044347A1/de not_active Ceased
- 2006-09-20 CN CN2006101530509A patent/CN1936073B/zh not_active Expired - Fee Related
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2009
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CN101810060B (zh) * | 2007-09-11 | 2012-10-03 | 赖茵豪森机械制造公司 | 用于表面处理或涂层的方法和设备 |
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CN101638560B (zh) * | 2008-03-31 | 2013-12-18 | 福特全球技术公司 | 结构聚合物插入物及其制造方法 |
CN103639157A (zh) * | 2013-11-15 | 2014-03-19 | 广州福耀玻璃有限公司 | 玻璃附件的表面处理方法 |
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CN105271805A (zh) * | 2014-06-20 | 2016-01-27 | 麒麟电子(深圳)有限公司 | 玻璃基板的塑胶粒喷洒设备及其塑胶粒喷洒方法 |
CN105271805B (zh) * | 2014-06-20 | 2018-01-16 | 麒麟电子(深圳)有限公司 | 玻璃基板的塑胶粒喷洒设备及其塑胶粒喷洒方法 |
CN107107102A (zh) * | 2015-01-13 | 2017-08-29 | Asi石英机械有限责任公司 | 增强的颗粒沉积系统和方法 |
CN107107102B (zh) * | 2015-01-13 | 2021-06-22 | Asi石英机械有限责任公司 | 增强的颗粒沉积系统和方法 |
Also Published As
Publication number | Publication date |
---|---|
TWI410389B (zh) | 2013-10-01 |
US8048530B2 (en) | 2011-11-01 |
GB2430395A (en) | 2007-03-28 |
US7517561B2 (en) | 2009-04-14 |
TW200728227A (en) | 2007-08-01 |
US20090155604A1 (en) | 2009-06-18 |
DE102006044347A1 (de) | 2007-03-22 |
GB2430395B (en) | 2011-11-23 |
CN1936073B (zh) | 2012-06-20 |
CA2559293C (en) | 2016-02-16 |
GB0616204D0 (en) | 2006-09-27 |
CA2559293A1 (en) | 2007-03-21 |
US20070065582A1 (en) | 2007-03-22 |
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