TW201417988A - 藉真空熱形成處理免於光學缺陷之汽車玻璃的製造 - Google Patents
藉真空熱形成處理免於光學缺陷之汽車玻璃的製造 Download PDFInfo
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Abstract
本發明說明用於從半成品的甲基丙烯酸甲酯(PMMA)產品中製造無光學缺陷的面板之處理的必要模具。本發明特別關於新穎的真空熱形成處理,其以經濟循環次數,從PMMA或聚碳酸酯(PC)製造具有特別良好光學品質的透明塑膠模製品。在從此處理移走時,這些模製品是尺寸上穩定的且無變形。透明的模製品更沒有呈現例如小丘等表面缺陷。
Description
本發明說明從半成品甲基丙烯酸甲酯(PMMA)產品製造免於光學缺陷的面板之處理的基本模具。本發明特別關於新穎的真空熱形成處理,其以經濟循環次數,從PMMA或聚碳酸酯(PC)製造具有特別良好光學品質的透明塑膠模製品。在從此處理移走時,這些模製品是尺寸上穩定的且無變形。透明的模製品更沒有呈現例如小丘等表面缺陷。也不需要先前技術中必須被施加至模中之例如潤滑劑或材料等任何添加物質。
為了降低石油消耗或是為了延長電動車的行程,汽車製造商及供應商將輕重量結構視為關鍵技術,因而增加它們的可接受度。此處另一日漸重要的因素是以塑膠取代玻璃。可能的重量減少於此是從40至50%。不僅已核准聚碳酸酯,也核准聚甲基丙烯酸甲酯製成的玻璃。塑膠製成的玻璃不僅減少重量,也增加設計自由度。以熱成形製程
製造玻璃迄今的問題已經是沒有小丘的熱成形玻璃是沒有可能性的。「小丘」大多涉及玻璃自熱成形模卸除後表面上的圓形缺陷。
已經有一些良好建立的處理,能製造作為例如汽車構造中的玻璃型式之聚碳酸酯(PC)或是甲基丙烯酸甲酯(PMMA)製成的透明模製品。但是,這些一般是對PC最佳化且對於PMMA處理具有主要的缺點,特別是當製造的單元的數目相當大時。
大數目的PC模製品單元可由注射-壓縮模製處理製造。舉例而言,此型式的注射-壓縮模製處理可以在4至5分鐘的循環中製造面積約為1.5m2之透明車頂。但是,PC的廢料率相當高。由於產品會具有高霾度,所以,無法處理PMMA。此型式的工廠要求的投資相當高,且低於10000單元/年之年產率是不經濟的。
另一方面,藉由垂延形成或是覆蓋形成,可以從PC或PMMA,製造小數目的單元。此處,以材料覆蓋模,然後,由例如PMMA製造的依尺寸切割的塑膠置於其上。在從115°至140°的溫度範圍之加熱爐中加熱之後,依尺寸切割的材料複製模的形狀,以及,在約4小時後(包含冷卻時間)移走。限定因素是加熱爐的尺寸並因而是加熱爐內的熱分佈。
整體而言,該處理是非常不積極的以及取得優良的光學品質結果。但是,由於此處理是非常耗時,其僅適用於最多1000單元/年的產出率。
真空熱形成處理代表用於製造塑膠模製品的替代方法。此處理的優點對短循環時間及低的產品廢料率是適當的。至此說明的本處理用以例如製造用於廣告產業的PMMA照明號誌或聚苯乙烯(PS)冰箱包覆。取得的光學品質是良好的,但是在汽車應用中仍然不適當,特別是作為玻璃;由真空熱形成製造的彎曲的、透明的塑膠模製品在聚合物基質中總是呈現高度應力。當經由產品觀視物體時,這些應力接著造成高度扭曲,以及,這些面板因而不適用於玻璃。這些塑膠模製品,特別是PMMA或PC製成的塑膠模製品,也通常具有表面缺陷,已知是凸丘。
慮及所述的先前技術,因此,本發明的的是提供新穎的處理,用於製造具有良好的光學品質之透明塑膠模製品,而不用使用例如潤滑劑等形成輔助品或是在模上覆蓋材料。
特別的企圖是該處理能夠以短循環時間及低廢料率或低產品缺陷操作。
另一企圖是處理對於1,000至100,000單元/年之平均產出率是經濟的。
本發明的特別目的是提供能夠製造表面沒有凸丘或其它缺陷、且同時在聚合物基質中沒有光學有關的應力之透明塑膠模製品的處理。
藉由提供新穎的真空熱形成處理,達成這些目的。該新穎處理首先以經濟循環時間製造用於例如汽車玻璃之透明模製品。該處理由下述步驟構成:a)模及透明塑膠製成的預製品之預先溫度控制,b)較佳地藉由壓縮空氣或是在次大氣壓之下,例如在真空中,該預製品的預模製,c)在例如真空等次大氣壓下,以透明塑膠的菲卡(Vicat)軟化點之上的模溫度,在模內成形,d)成形模的冷卻,以及組件的冷卻,以及e)透明模製品的移走
藉由可變溫(Variotherm)模具的感應、或是IR照射或是電管形加熱器,較佳地取得步驟a)中的預先溫度控制。
一般而言,藉由真空形成處理而高品質地製造之此型的透明模製品之事實本與已令人驚訝。根據先前技術之真空熱形成處理而製造的模製品在聚合物基質中呈現相當高度的應力,這接著對經由面板觀視影像的觀視者會導致相當高度的變形。令人驚訝的是,發現根據本發明的處理能夠避免這些應力,因此能夠製造高度地無變形之具有高光學品質的彎曲面板。
令人驚訝的是,也發現假使在步驟c)中將模具的溫度
控制在菲卡軟化點以上的溫度時,與凸丘化有關的表面之光學品質顯著地增加。
本發明的另一成就是藉由增加的步驟d)完成的模製品在尺寸上是穩定的以及因而能夠從模具中可運送地移走。因此,必須能夠在相同的模具區中執行步驟c)及d)。在用以執行步驟c)之仍然閉合的、模具區中結束成形後,取得冷卻。
本發明的另一優點是獨立於組件的尺寸之外,能夠取得小於10分鐘的循環時間,特別是小於6分鐘,以及,假使又最佳化,小於4分鐘。
從本發明取得的另一令人驚訝的優點是不使用例如在模具表面上的潤滑劑或是覆蓋材料等形成輔助。這接著有助於又增加表面品質。
在一特定實施例中,借助於單站真空熱形成機器,執行根據本發明的處理。當考慮能用於真空熱形成處理的模具時,通常在單站與多站機器之間作出區別。在單站機器的情形中,或是更精確而言,單站真空熱形成機器的情形中,在相同模具中,步驟a)至d)發生。另一方面,在多站機器中,或是在多站真空熱形成機器中,步驟a)、b)及c)分別在分別的模具區中發生。至少步驟a)的一般程序與其它步驟在空間上是分開的,而步驟b)至d)或是至少步c)及d)發生在相同模具區中。根據本發明的處理在原理上可以在任何上述的機器中實施。
單站工具或是多站工具又具有其它附加的工具組件,
舉例而言,衝床及堆料機。在1986年第2版之Hanser Verlag,Munich所著之Becker,Braun,Kunststoff-Handbuch Polyvinylchlorid 2/2[Plastics Handbook,Polyvinyl chloride 2/2]中,可找到原理上適用於真空熱形成處理的此型式的真空熱形成機的各種元件有關的資訊。
透明塑膠較佳地涉及甲基丙烯酸甲酯(PMMA)或是聚碳酸酯(PC)。同樣較佳地,涉及PMMA及PC的混合物,或是PMMA或PC與一或更多其它構成物的混合物。該其它組成物特別涉及聚偏二氟乙烯(PVDF)。
PMMA涉及純PMMA或是涉及MMA與高達20%重量的其它共聚單體之共聚物,例如,特別是丙稀酸的烴基酯,以作為基質材料。與基質材料一起,PMMA包括高達80%重量的衝擊調節劑,較佳地(甲基)丙烯酸酯為基礎的內核-外殼或是內核-外殼-外殼粒子。此處之(甲基)丙烯酸酯說明包括甲基丙烯酸酯、丙烯酸酯、及特別是丙烯酸酯與甲基丙烯酸酯的混合物。
根據本發明之預製品及由其製造的模製品包括沿著聚合組成物之其它添加的物質,例如,處理輔助物、穩定物、或添加物聚合組成物:舉例而言,紫外線吸收物及/或紅外線吸收物或是紫外線穩定物可以存在。染料也存在,但是,這些不被允許造成霾。也可添加增進抗刮性的添加物。舉例而言,處理輔助涉及流變調節劑、流體輔助或是散佈劑。
在本發明的另一實施例中,預製品涉及透明塑膠製成
的多層預製品。此處,這些層中至少之一是由PMMA或PC構成。其它層相等地由PMMA或PC或是例如PVDF等其它塑膠構成。
在步驟e)中移走之後及/或之前,模製品也又被塗著。在移走之前的塗著意指塗著發生在步驟b)之前或期間、或是較佳地在步驟c)期間。此外,有一些可能的變異。首先,在導入預製品之後,將用於塗著的材料導入或注入模具中。其次,用於塗著的材料以箔型式的形狀預先設置於模具中,或是之前置於預製品上。在另一可能性中,模具的內側的表面預先設置塗層。預製品也在導入模具中之前被塗著。但是,後一變異由於因為成形處而造成不均勻塗著,所以是比較不較佳的。
在較佳的處理中,在步驟c)期間,模製品設有塗層,以及,其中,該塗層預先設於模具表面上。
塗層涉及習於此技藝者熟知的各式各樣的塗層。因此,下述實例無論如何絕非限定本發明;舉例而言,塗層良好地涉及透明有色層以實現有色玻璃。舉例而言,在汽車玻璃的情形中,塗層也良好地包括UV吸收器及/或IR吸收器以降低車輛內部的熱。塗層也包涉及抗刮塗層及/或抗污塗層。特別較佳的是執行二或更多所述功能之塗層。
在處理結束之後,模製品接受進一步處理:在一可能中,舉例而言,在移走後,模製品在邊緣處被切割至符合尺寸及/或拋光。在另一可能性中,完成的模製品於一或
二側上完全地或某程度地設有保護箔。因而在儲存或運輸期間可以避免損傷。
較佳的是,循環地製造眾多模製品的處理;在也取得更短的循環時間本發明一特定實施例中,在移走後從模製品切割眾多產品構件。藉由使用僅一個模具,模製品的產量因而倍數地增加。
本發明不僅提供處理,也提供申請專利範圍的處理所製造的透明模製品之用途。這些申請專利範圍的用途特別涉及汽車玻璃、建築物的窗戶、或是燈罩、或一般而言為裝飾元件。
接著,說明使用真空熱形成以製造無光學缺陷之印製的汽車玻璃之規格實例。
預先印製的半成品(例如,來自Proell的Noricryl)置於真空熱形成機器中(例如,來自Geiss的T9)。輻射加熱器將基底加熱。由石英玻璃製成的輻射加熱器用於此目的,或是Speedium輻射加熱器。在加熱程序期間,夾緊框維持非常輕微的打開,且當基底的溫度達到約115℃時其最後關閉。
一旦設於機器中的切割符合尺寸區的加熱結束時,預拉伸程序接著開始。以超過或次大氣壓用於此。此處決定性的因素是結果的圓罩已經幾乎複製模具的形狀。
一旦預拉伸程序結束時,模具移入圓形罩。重要的
是,模具的溫度被控制在110℃至140℃的溫度範圍,以致於也後續在塑膠/PMMA接觸側上確保高表面品質(A等級的表面)。
然後,施加真空,以使被加熱的基底與被加熱的模具緊密接觸,以及,複製模具。
在某固持時間之後,機器開始使用鼓風機以將基底從上述溫度冷卻,同時,也將模具調整至顯著地在菲卡點之下的溫度,以及,模具因而有助於冷卻處理。
一旦基底的溫度在長期操作溫度之下時,開始從模具移走的程序。不用導因於模具的冷卻,模具的高溫會造成模具加熱,這喪失其從模具移走的尺寸準確度。一旦真空關閉時,模具返回至基本位置。一旦這發生時,夾緊框也返回至基本位置,因而移開完成的模製品。
Claims (14)
- 一種真空熱形成處理,用於製造透明的模製品,其特徵在於處理包括下述步驟:a)模具以及透明塑膠製成的預製品的預先溫度控制,b)該預製品的預模製,c)在次大氣壓及在該透明塑膠的菲卡軟化點之上的模具溫度之中,在該模具內成形,d)成形模具的冷卻、以及組件也冷卻,以及e)該透明模製品移走。
- 如申請專利範圍第1項之處理,其中,壓縮空氣用於步驟b)中的該預模製。
- 如申請專利範圍第1項之處理,其中,真空用於步驟b)中的該預模製及/或用於步驟c)中的該成形。
- 如申請專利範圍第1項之處理,其中,藉由可變溫(Variotherm)模具的感應、紅外線照射、或是電管形加熱器,達成步驟a)中的該預先溫度控制。
- 如申請專利範圍第1項之處理,其中,該透明塑膠涉及甲基丙烯酸甲酯(PMMA)或是涉及聚碳酸酯(PC)或是涉及PMMA、PC及其它構成物的混合物。
- 如申請專利範圍第1項之處理,其中,該預製品涉及透明塑膠製成的多層預製品,其中,該多層的至少一層由PMMA或是PC構成。
- 如申請專利範圍第1項之處理,其中,在移走之後及/或之前,該模製品也被塗著。
- 如申請專利範圍第1項之處理,其中,在步驟c)中,該模製品設有塗層,以及,其中,該塗層先前地設於該模具表面上。
- 如申請專利範圍第1項之處理,其中,在移走後,該模製品在邊緣處被拋光及/或切割至符合尺寸。
- 如申請專利範圍第1項之處理,其中,在移走之後,從模製品切割出複數個產品構件。
- 如申請專利範圍第1項之處理,其中,循環地製造複數個模製品。
- 如申請專利範圍第1項之處理,其中,該預製品於一或二側上完全地或某程度地設有保護箔。
- 如申請專利範圍第1項之處理,其中,藉由單一站真空熱形成機之助,執行該處理。
- 一種透明模製品的用途,該透明模製品由根據申請專利範圍第1至13項中至少一項製造,該透明模製品用於汽車玻璃、建築物的窗戶、燈罩、或裝飾元件。
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