TW202146228A - 預成形窗膜及其製造與使用方法 - Google Patents
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Abstract
敘述一種預成形窗膜。具體而言,描述包括窗膜層、壓敏性黏著劑、及襯墊之預成形窗膜。預成形窗膜經拉伸使其a)不會平攤在一平坦表面上而無皺摺,且b)在繃緊時,具有一形狀,該形狀在至少兩個垂直方向上具有一曲率。
Description
某些窗膜係用於汽車及建築物應用中以提供物理保護及/或所欲的光學性能。舉例而言,一些窗膜可阻擋紅外線、紫外線、及/或可見光之一部分通過彼等窗。對於建築物窗而言,窗表面一般而言係平坦的。然而,某些建築物窗及許多汽車窗的表面係彎曲的。施加窗膜至這些彎曲表面需要高度技術性的安裝及許多時間。
在一態樣中,本說明書係關於一預成形窗膜。該預成形窗膜包括一窗膜層,該窗膜包括至少一可見光或紅外線吸收或反射材料;一壓敏性黏著劑層,其與該窗膜層接觸;及一襯墊,其與該壓敏性黏著劑層接觸。該預成形窗膜經拉伸使其a)不會平攤在一平坦表面上而無皺摺,且b)在繃緊時,具有一形狀,該形狀在至少兩個垂直方向上具有一曲率。
在另一態樣中,本說明書係關於一種施加一預成形窗膜之方法,該方法依次包括下列步驟:提供包括一窗膜層之一預成形窗
膜,該窗膜層包括至少一可見光或紅外線吸收或反射材料、與該窗膜層接觸之一壓敏性黏著劑層、以及與該壓敏性黏著劑層接觸之一襯墊,其中該預成形窗膜經拉伸使其a)不會平攤在一平坦表面上而無皺摺,且b)在繃緊時,具有一形狀,該形狀在至少兩個垂直方向上具有一曲率,且接著自該預成形窗膜移除該襯墊,且接著施加該預成形窗膜至一窗,該窗在至少兩個垂直方向上具有一曲率。
在又另一態樣中,本說明書係關於一種預形成一窗膜之方法,其依次包含以下步驟:提供一窗膜區段,該窗膜區段包括一窗膜層,該窗膜層包括至少一可見光或紅外線吸收或反射材料、與該窗膜層接觸之一壓敏性黏著劑層、以及與該壓敏性黏著劑層接觸之一襯墊,且接著在一工具上方拉伸該窗膜區段,且接著自該工具移除該窗膜以產生一預成形窗膜,該預成形窗膜透過拉伸而具有一變形,使其a)不會平攤在一平坦表面上而無皺摺,且b)在繃緊時,具有在至少兩個垂直方向上具有一曲率的一形狀。
10:窗膜區段
12:窗膜層
14:壓敏性黏著劑
16:襯墊
200:預成形窗膜
310:窗膜區段
320:工具
410:窗膜區段
420:窗
〔圖1〕係習知窗膜區段之示意側立視截面圖。
〔圖2〕係預成形窗膜之示意俯視透視圖。
〔圖3A〕及〔圖3B〕係形成預成形窗膜之方法之步驟的示意圖解。
〔圖4〕係施加預成形窗膜之方法的示意圖解。
圖1係習知窗膜區段之示意側立視截面圖。窗膜區段10包括窗膜層12、壓敏性黏著劑14、及襯墊16。通常,窗膜習知地係成卷販售、運輸、及儲存,並且將其切至其欲安裝於其上之特定窗戶。一習知窗膜可具有任何合適的形狀及大小,但其攤開為平坦(無皺摺)且通常係平面的。
習知上,一窗膜包括一窗膜層12,該窗膜層主要負責窗膜之光學效能。在一些實施例中,窗膜層可包含一多層光學膜。多層光學膜包括光學微層之重複圖案,該等光學微層經由具有不同折射率之相鄰微層之間的相長推論(constructive inference),有效地反射光的一或兩個偏振。該等反射波長取決於該等層之實體厚度(亦即,光學厚度)及折射率。多層光學膜已知為為市售膜中的組件,其主要反射可見光,諸如Enhanced Specular Reflector(可購自3M Company,St.Paul,Minn.),及主要反射紅外光的膜,諸如Automotive Window Film Crystalline Series窗膜(可購自3M Company,St.Paul,Minn.)。
為了附貼至所欲基材或表面(一般係玻璃或塑膠窗或其他透明表面),習知窗膜亦包括壓敏性黏著劑12,以容易地黏附窗膜層而不需要複雜之黏著劑塗布、乾燥、及/或固化的設備。當安裝係在一工作場所或一汽車包膜店完成,而該等場域不太可能提供此類設備時,此係有利的。
襯墊14係提供在窗膜之原本經暴露表面上,以允許在成卷的方式運輸該窗膜,並在處理、轉換、測量、或切割時防止非所
欲的黏著及碎屑累積。一般而言,襯墊係可移除離型襯墊,其可經手動移除或作為一連續製程的一部分而移除而無需過高要求的剝離強度。襯墊一般係紙或塑膠,包括可選的離型塗層,其可係聚矽氧或另一種低表面能材料,以從黏著劑輕易地釋離。
安裝習知窗膜的挑戰在於,其需要特定的技術、專業訓練、及許多時間。習知上,將窗膜,尤其意欲安裝於一複雜彎曲表面上(亦即,同時在兩個垂直方向上具有曲率的表面)的窗膜,切割或提供為尺寸過大片,並且接著通過加熱縮小以適配。通常多餘之膜的「指狀物(finger)」必須經熱收縮,以提供良好且平滑的適配度。此一類嚴苛的安裝程序可相當地增加勞力成本及一間商店可執行的安裝量。進一步,此一安裝程序對於具有高度曲率的窗而言變得更加困難。
圖2係預成形窗膜之示意俯視透視圖。預成形窗膜200係窗膜之一離散區段。在一些實施例中,預成形窗膜200可經定大小以適配於特定選定之窗或其他目標表面上。在一些實施例中,預成形窗膜200可係大略矩形,但任何合適的形狀皆係可行的。
預成形窗膜200包括與一習知窗膜相同之關鍵組成:包括一窗膜層、一壓敏性黏著劑層、及一襯墊。然而,預成形窗膜獨特之處在於其已經受拉伸或變形。該預成形窗膜已經經拉伸或變形,使得該預成形窗膜不會平攤在一平坦表面上而無皺摺。雖然窗膜的剛性可能不足以維持完全三維形狀,但變形造成窗膜在按壓或平攤時起皺褶。然而,其原始形狀或其在繃緊時保持的形狀包括在至少兩個垂直
方向上的曲率。在其他情況下,其經拉伸或經隱含之形狀係包括在至少兩個垂直方向上之曲率的形狀。
該拉伸可在某些地方造成輕微的物理性薄化。例如,在邊緣處之膜的卡尺厚度可比相同膜之中心附近的卡尺厚度更薄。在一些實施例中,在中心處之膜的卡尺厚度可比相同膜之邊緣附近的卡尺厚度更薄。
預成形窗膜的經拉伸形狀允許在複雜彎曲表面上達成更加簡易地安裝。在一些實施例中,此形狀允許在不加熱的情況下安裝預成形窗膜。
在一些實施例中,預成形窗膜200包括一窗膜層,該窗膜層包括一光吸收顏料,諸如碳黑或一陶瓷顏料。在一些實施例中,預成形窗膜200包括一窗膜層,該窗膜層包括一反射多層光學膜。在一些實施例中,預成形窗膜200包括一膠黏的壓敏性黏著劑。
在一些實施例中,預成形窗膜200包括一窗膜層及一襯墊,其等以相同或接近相同(在20%內、在10%內、在5%內,或甚至在1%內)的程度和速率拉伸。在一些實施例中,這意味著與襯墊一起拉伸之窗膜層不會導致襯墊自壓敏性黏著劑層脫層,且允許襯墊保持與壓敏性黏著劑層緊密接觸。在一些實施例中,這意味著在襯墊與壓敏性黏著劑層之間沒有氣隙或脫層。
圖3A及圖3B係形成預成形窗膜之方法之步驟的示意圖解。大體而言,窗膜區段310經按壓或接觸至工具320,以變形或拉伸該窗膜區段,使其永久改變。
在一些實施例中,窗膜區段310在一熱成型程序中與工具320接觸。在一些實施例中,窗膜區段310在部分真空的存在下與工具320接觸。可使用任何合適的熱成型程序(及/或裝置)。在一些實施例中,窗膜區段及/或工具經加熱。在一些實施例中,施加的熱使窗膜區段之一或多個層的溫度增加超過其玻璃轉移溫度。在一些實施例中,窗膜層、壓敏性黏著劑值、及襯墊中的一或多者可具有不同的收縮值。
在一些實施例中,工具320係玻璃。在一些實施例中,工具320係窗的一複製品或完全相同於窗,該窗將最終安裝有窗膜區段於其上。在一些實施例中,工具320係意欲且用作一正工具(凸形)。在一些實施例中,工具320係意欲且用作一負工具(凹形)。在一些實施例中,窗膜區段310首先接觸至工具320,使得窗膜區段之襯墊與工具320接觸。此可作為用於光學功能的保護層(換言之,因為襯墊會被丟棄,因熱成型及/或處理所造成之擦痕或其他缺陷不影響最終安裝品質)。
在一些實施例中,窗膜區段310係一連續卷的一部分(亦即,窗膜在其經熱成形或以其他方式抵靠該工具受模製時尚未經轉換)。在拉伸一連續卷的情況中,可適當地使用夾或其他機構以使經拉伸或形成的部分與其他的部分相隔離。在此類情況中,該窗膜可在運輸前(例如,經轉換之窗膜片以片材堆疊運送)、在安裝場所處、或在模製與安裝之間的轉換點或專門分銷處經裁剪分離。因為該襯墊係
完整且經熱成型附接,所以對於經拉伸膜之處理及運輸有較大彈性。換言之,其未在相同步驟中變形並黏附。
在成形且將窗膜自工具移除之後,產生一預成形窗膜。該預成形窗膜透過拉伸現在具有一變形,使該預成形窗膜a)不會平攤在一平坦表面上而無皺摺,且b)在繃緊時,具有一形狀,該形狀在至少兩個垂直方向上具有曲率。窗膜可經轉換及/或裁剪成所欲大小及形狀。
圖4係施加預成形窗膜之方法的示意圖解。圖4繪示將其襯墊已移除的一窗膜區段410黏附至一窗420之一表面,該窗在兩個垂直方向上具有曲率。窗膜經拉伸使得其a)不會平攤在一平坦表面上而無皺摺,且b)在繃緊時,具有一形狀,該形狀在至少兩個垂直方向上具有曲率。在一些實施例中,此曲率對應於該窗之曲率。窗420可係任何適合的窗戶或擋風玻璃。在一些實施例中,窗420可係一交通運輸車輛(諸如汽車、卡車、火車、飛機、或巴士)之側窗或前方或後方的擋風玻璃。在一些實施例中,窗420可係建築物或建築窗。
在一些實施例中,可施加額外的乾燥或固化程序以從膜移除被困的氣泡或幫助壓敏性黏著劑產生持久的接合。亦可進行適當清潔程序以預備窗戶。在一些實施例中,不需要熱的施加以使窗膜縮小而適配。
在一些實施例中,該預成形窗膜係施加至一彎曲窗之內表面(凹)表面。在一些實施例中,雖然在圖4中未具體繪示,該預成形窗膜係施加至一彎曲窗之外部(凸)表面。
除非另外指示,否則對圖式中元件之描述應理解成同樣適用於其他圖式中相對應的元件。本發明並不侷限於上文闡述之實例及實施例的具體揭示,因為詳細描述這些實施例是為了利於解說本發明的各種態樣。而是,應理解本發明涵蓋本發明的所有態樣,包括屬於如隨附申請專利範圍與其均等物所界定的本發明範疇內的各種修改、均等程序、和替代裝置。
200:預成形窗膜
Claims (28)
- 一種預成形窗膜,其包含:一窗膜層,該窗膜層包括至少一可見光或紅外線吸收或反射材料;一壓敏性黏著劑層,其與該窗膜層接觸;及一襯墊,其與該壓敏性黏著劑層接觸;其中該預成形窗膜係經拉伸使其a)不會平攤在一平坦表面上而無皺摺,且b)在繃緊時,具有一形狀,該形狀在至少兩個垂直方向上具有一曲率。
- 如請求項1之預成形窗膜,其中該窗膜層包括一反射多層光學膜。
- 如請求項1之預成形窗膜,其中該窗膜層包括碳黑。
- 如請求項1之預成形窗膜,其中該窗膜層包括一陶瓷顏料。
- 如請求項1之預成形窗膜,其中該襯墊係一可移除離型襯墊。
- 如請求項1之預成形窗膜,其中該襯墊以與該窗膜層大約相同的速率及程度拉伸。
- 如請求項1之預成形窗膜層,其中該襯墊與該壓敏性黏著劑層緊 密接觸。
- 如請求項1之預成形窗膜,其中該壓敏性層係膠黏的。
- 一種施加一預成形窗膜之方法,其依序包含以下步驟:i.提供一預成形窗膜,該預成形窗膜包括:一窗膜層,該窗膜層包括至少一可見光或紅外線吸收材料;一壓敏性黏著劑層,其與該窗膜層接觸;及一襯墊,其與該壓敏性黏著劑層接觸;其中該預成形窗膜係經拉伸使其a)不會平攤在一平坦表面上而無皺摺,且b)在繃緊時,具有一形狀,該形狀在至少兩個垂直方向上具有一曲率;ii.自該預成形窗膜移除該襯墊;iii.施加該預成形窗膜至一窗,該窗具有在至少兩個垂直方向上之一曲率。
- 如請求項9之方法,其中施加該預成形窗膜至一窗戶不需要熱的施加。
- 如請求項9之方法,其中施加該預成形窗膜至一窗戶使用熱的施加。
- 如請求項9之方法,其中該窗係一交通運輸車輛之一前方或後方擋風玻璃。
- 如請求項9之方法,其中該窗係一交通運輸車輛之一側窗。
- 如請求項9之方法,其中該預成形窗膜係施加至該窗之一內部表面。
- 如請求項9之方法,其中該預成形窗膜係施加至該窗之該外部表面。
- 如請求項9之方法,其中該預成形窗膜係施加至該窗之一凸表面。
- 如請求項9之方法,其中該預成形窗膜係施加至該窗之一凹表面。
- 一種預形成一窗膜之方法,其依序包含以下步驟:i.提供一窗膜區段,該窗膜區段包括一窗膜層,該窗膜層包括至少一可見光或紅外線吸收材料;一壓敏性黏著劑層,其與該窗膜層接觸;及一襯墊,其與該壓敏性黏著劑層接觸;ii.在一工具上方拉伸該窗膜區段;iii.自該工具移除該窗膜以產生一預成形窗膜;該預成形窗膜透過拉伸具有一變形,使其a)不會平攤在一平坦表面上而無皺摺,且b)在繃緊時,具有在至少兩個垂直方向上具有一曲率的一形狀。
- 如請求項18之方法,其中該工具為正工具。
- 如請求項18之方法,其中該工具為負工具。
- 如請求項18之方法,其中該工具包括玻璃。
- 如請求項18之方法,其中該工具係一車輛窗戶或擋風玻璃。
- 如請求項18之方法,其中在一工具上方拉伸該窗膜包括一熱成型程序。
- 如請求項18之方法,其中在一工具上方拉伸該窗膜包括將該窗膜區段之該襯墊側放置為與該工具接觸。
- 如請求項18之方法,其中在一工具上方拉伸該窗膜包括熱的施加。
- 如請求項18之方法,其進一步包含將該預成形窗膜施加至一窗戶之步驟。
- 如請求項18之方法,其中該窗戶具有與該工具相同之形狀與大小。
- 如請求項18之方法,其中將該預成形窗膜施加至該窗戶不需要熱的施加。
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