TWI410389B - 塗佈一基材以用於黏結之方法 - Google Patents
塗佈一基材以用於黏結之方法 Download PDFInfo
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- TWI410389B TWI410389B TW95132893A TW95132893A TWI410389B TW I410389 B TWI410389 B TW I410389B TW 95132893 A TW95132893 A TW 95132893A TW 95132893 A TW95132893 A TW 95132893A TW I410389 B TWI410389 B TW I410389B
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- Prior art keywords
- coating
- prepolymer
- group
- glass surface
- high velocity
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Classifications
-
- 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
- C03C23/00—Other surface treatment of glass not in the form of fibres or filaments
- C03C23/0075—Cleaning of glass
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
- B32B17/10018—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising only one glass sheet
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/10688—Adjustment of the adherence to the glass layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- 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
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- 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
- B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
-
- 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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Description
本發明之一個態樣係關於一種塗佈一基材用於黏結之方法。
在生產許多物品中，往往有必要接合不同材料。在多數情況下，該等材料之一或兩者必須調整其表面性質。在製造業中，調整材料之表面性質往往涉及表面處理技術。此等表面性質之非限制實例包含表面能、化學惰性、傳導性、接收染料性及黏著力。使用表面處理及製備之塗覆的非限制實例包含在諸如鐵及鋼之可腐蝕性金屬上的防蝕塗層；在植入物上的生物相容性塗層；在電子器械上的防水層；及在玻璃上的黏接劑。
塗覆塗層、黏接劑、封閉劑及彈性體(CASE)於基材往往需要在處理或預處理表面中特別小心以避免基材與所塗覆之CASE化合物之間的黏著失效。多數CASE塗覆過程涉及步驟(a)清理或粗糙化表面，(b)塗覆一黏結至表面或蝕刻表面之底塗劑，及(c)塗覆一增加額外黏結功能之增強劑。CASE化合物用於包含建築、汽車、醫學、牙科、標籤、電子學及包裝之行業中。
在汽車工業中，CASE化合物與玻璃裝配過程結合使用。不利地，汽車玻璃窗玻璃易因衝擊其邊緣之機械震動而破裂。因而，邊緣通常封裝。在一種封裝方法中，一框架將汽車玻璃窗玻璃連接至車的上部結構。因此該框架鄰接一部分玻璃。在一種用於黏結玻璃與框架組件之方法中，玻璃窗玻璃以一溶劑清理，一含有偶合劑以化學改質表面之底塗劑塗覆於該表面，及最後，塗覆一層較厚之充分黏結至框架之類塗料化合物。在此實例中，由於當乾燥時，底塗劑在玻璃上顯著變得透明且第二塗層不透明，從而當塗覆寬度比底塗劑塗層之寬度寬時，阻礙精確對準，因此適當對準兩層(意即底塗劑與類塗料化合物)存在困難。
當玻璃窗玻璃用作一風擋時，其意欲防止諸如風、雨、碎片及紅外線加熱之物質及能量轉移至車廂中，而在車輛碰撞及傾翻情況期間藉由增加結構整體性，有助於乘客安全。在某些情況下，由於其可在某些區域具有燒結以遮蔽紅外線、紫外線及其他波長之光線，因此玻璃窗玻璃並非均質表面。同樣，其可具有有色區域。另外，其可在此等特徵中具有間隙以容許施用扣件。此等間隙在塗覆第二層封閉劑期間可需要耗費勞動的掩蔽(labor－intensive masking)。
接合不同材料之其他態樣包含期望改良製造精確度、生產力、自動化水平、可靠性，及/或可製造性，同時降低不良副效應、所使用材料之數量，及/或能量及材料之消耗。例如，有些CASE化合物造成大量浪費。往往偶合劑底塗劑為小於1%活性劑及99%載體溶劑。在另一實施例中，清理材料具有不良副效應，諸如易燃性及/或諸如異丙醇或甲苯之有毒溶劑。在其他情況下，類塗料層往往必須在30秒鐘內風乾及因此使用揮發性溶劑。整治此等散發物及保護勞動者健康需耗費能量及金錢。
最近，電漿聚合已發展成為改質材料表面之工具以改良可製造性、自動化水平，及製造精確度，同時降低不良副效應及能量與材料之消耗。
存在由其輸出溫度、其壓力條件，及關於化學與熱態之平衡態所定義的不同類型之電漿。例如，在低於環境壓力條件下，產生電漿。實例包含以通常用於物理蒸汽沈積中之磁控管所產生之高電漿密度模式及低電漿密度模式電漿。其他環境壓力之實例包含輝光放電、感應耦合及再結合電漿。輝光放電由幾公尺/秒之氣體之低速移動表徵。其展示熱與化學兩者之不平衡。一感應耦合電漿具有低速至中速氣體移動。其展示局部熱平衡。再結合之氮氣或空氣電漿具有大約1 km/sec之高氣體速度及展示化學平衡。電漿類別之額外實例由諸如微波諧振及放電之其離子化方法決定。
當電漿應用於實驗室外之大量生產過程中時，產生額外可製造性及自動化考慮因素，諸如操作速度、與基材之相容性，及污染。
在多數應用中，電漿處理發生迅速，通常大約若干奈秒至幾分鐘，其實際上排除諸如物理蒸汽沈積之分批真空技術。
高溫電漿可熱燃燒或熱衝擊基材，尤其具有低熱導率及低熔點或燃燒點之基材。
另外，有些表面為不理想的，諸如具有粉塵、有機體油，及來自裝運及裝卸之碎片之彼等表面。
根據以上所述，需要一種用於一製備一供接合兩種不同材料或接收CASE化合物之表面之大量生產過程的方法，其改良製造精確度、生產力、自動化水平、可靠性，及/或可製造性同時降低不良副效應、所使用之材料數量，及/或能量與材料消耗。
本發明之一實施例為一種方法，在第一段時間期間沈積一塗層，其中表面係經清理，且使用一常壓空氣電漿(APAP)在第二段時間期間在環境氣壓下，沈積一高速衝擊聚合反應塗層於表面上。
本發明之另一實施例為一種塗覆一塗層之方法，其涉及混合預聚物蒸汽與載氣或作為小液滴霧狀物、將彼混合物導入常壓空氣電漿以形成聚合反應化合物，且接著用由常壓空氣電漿之排放氣體所驅動之高速衝擊來塗覆聚合反應化合物。
本發明另一實施例為一經塗佈之玻璃表面，其具有諸如新或較舊的風擋之玻璃表面，清理後，使用常壓空氣電漿將高速衝擊聚合反應塗層直接塗覆於該玻璃表面上。此實施例之額外態樣包含具有諸如封閉劑之第二層以接合不同材料，例如風擋及框架。此實施例之另一態樣包含，使用多個行進路徑或在大體上連續或大體上並行之行進路徑中行進之多個APAP，在一表面上產生高速衝擊聚合反應塗層的複合沈積。
請詳細參考發明者已知之本發明之組合物、實施例及方法。然而，應瞭解所揭示的實施例僅僅例示可以多種及替代形式體現之本發明。因此，並不將本文所揭示之特定細節理解為限制性，而僅僅為用於教示熟習此項技術者以多種方式使用本發明之代表性依據。
除非明確指示，否則在此說明書中將指示材料數量或反應及/或使用條件之所有數值數量理解為在描述本發明之最寬範疇中，由字"約"所限制。通常較佳在所規定之數值限制內實行。
適於本發明相關之特定目的之一組或類材料之描述意味該組或類的任何兩個或兩個以上成員的混合物為適合的。以化學術語描述之組份係指向說明書中所規定的任何組合添加時之組份，且並無必要排除所混合的混合物的組份中的化學相互作用。簡稱或其他縮寫之第一定義應用於在本文中的所有隨後使用的相同縮寫，且在作了適當修正後(mutatis mutandis)應用於最初所定義之縮寫的正規語法變化。除非明確規定相反情況，否則性質之量測由與先前或以後對於相同性質所涉及的相同技術決定。
圖1展示具有不同材料接合區域之汽車1，其包含風擋8、側窗9、天窗13、後窗，及後視鏡11。使用塗層、黏接劑、封閉劑，及彈性體之其他區域包含但不受限於金屬表面，諸如輪轂罩18；用於裝飾之彈性壓條14；內部車體部分；天窗密封件12；在引擎蓋下，用於引擎控制之電子電路板16；塑膠儀錶板20且可接收塗料；及磨損表面。
汽車玻璃窗風擋系統可包含一附著於車體上部系統2之框架4、一封閉劑、一底塗劑，及一玻璃表面。風擋8之玻璃表面可包含一玻璃料(frit)10及/或一有色區6。系統之其他實例可包括一彈性壓條、一塗覆於此壓條之黏接劑；一組件部分或一在引擎蓋下，連接至車電力系統之具有防水塗層的電子電路板。
參考圖2，在一常壓空氣電漿(APAP)系統中，在原料容器22中以預聚物形式之可聚合材料供應於管30中，其使用質量流量控制器32計量，及汽化且與在混合腔室38中之載氣混合。載氣自載氣原料容器36供應且經由計量表34導入混合腔室38中。此混合物導入含有離子化氣體之電漿之常壓空氣電漿裝置44中。離子化氣體經由計量表42來自離子化氣體原料容器40。空氣電漿裝置周圍之環境氣壓自大於50千帕斯卡(kilopascal)、75千帕斯卡或100千帕斯卡及小於300千帕斯卡、250千帕斯卡、200千帕斯卡，或150千帕斯卡變化。在排放噴嘴50處，高速聚合反應塗料可達到大於10 m/s、50 m/s，或75 m/s，及小於200 m/s、150 m/s，或125 m/s之速度。排出噴嘴50之氣體在小於450℃、400℃、350℃、325℃，或300℃及大於70℃、100℃、125℃，或150℃之溫度下；而基材的溫度視操作條件可小於95℃、85℃、75℃、70℃、65℃、60℃、55℃，或50℃。在基材處之此溫度允許此過程對易受熱損之基材進行加工。
自排放噴嘴50之氣體形成具有外部半影56之噴霧圖案，該外部半影56具有用於清理及/或活化的主要離子化氣體。較接近於噴霧圖案中心的為高速衝擊聚合反應塗佈材料之較高濃度區54。接收高速衝擊聚合反應塗層62之表面58為具有陶瓷燒結60及有色玻璃64之汽車玻璃窗玻璃風擋28。風擋封裝於框架66內。
接收該層之表面可由離子化及加熱活化且可在清潔條件中，具有碎片覆蓋物，或可熔蝕。表面可由常壓空氣電漿清理且部分活化。常壓空氣電漿自身之可能清理及活化機制可包含修復風化玻璃之鹼金屬耗盡層、離子化表面、改變表面能、燃燒油及粉塵或其組合。當常壓空氣電漿亦為一沈積本發明之一個實施例之高速衝擊聚合物塗層的設備時，自噴嘴排出的常壓空氣電漿的半影可具有與離子化及加熱相關的清理功能。因此，在此實施例中，在清理及/或活化步驟與沈積步驟之間的時段大於1 μs、5 μs、10 μs、25 μs，或100 μs。
本發明之另一實施例包含具有一或多個分離的常壓空氣電漿以清理及/或活化表面，繼而一或多個分離的常壓空氣電漿高速率沈積於衝擊聚合塗層中。可以連續方式、以並行方式或其組合操作APAP。當作為並行組之多個APAP操作時，典型間距可為約2 mm。
與沈積操作或經組合的清理及/或活化及沈積操作相比，清理及/或活化操作可在較高行進速度下操作。此等實施例之其他態樣可包含具有使用較寬通道之清理操作及使用其光柵型通道之沈積操作。清理及/或活化操作可使用諸如電暈放電或燃燒源之離子化技術達成。根據此實施例，清理/活化步驟與沈積之間的時段大於0.1 s、1 s、5 s、10 s、25 s，或100 s及小於150 s、300 s、10 min、30 min、1 hr、12 hr、1天、2天，或5天。
一額外實施例包含發展預聚物梯度之能力，其中儲存其他預聚物之額外原料容器24經由供應線26饋料給預聚物原料容器22以增量地調整預聚物在原料中的比率。本發明之一額外態樣具有其他預聚物，其經由供應線28饋料給可根據預聚物之比率增量地或逐步地調整之計量設備32。
在某些實施例中，APAP可傳遞電漿空氣處理至表面塗層以再活化表面塗層。例如，表面可清理且塗佈於一個位置，且接著運送至第二位置用於在稍後時間再活化。
參考圖3，在本發明之一實施例中，表面68具有由高速衝擊聚合反應塗層70與在分離步驟中所塗覆的CASE化合物72所形成的層化複合物，以將不同材料之表面68連接至框架74的一部分。由於在隨後的高速衝擊聚合反應塗層之光柵沈積期間，光輻射76經過附近，因此CASE化合物由自APAP 78之光輻射76硬化。
參考圖4，在本發明之另一實施例中，一層化複合物形成以保護電子電路板80及其焊柄86使之免於水、其他流體及蒸汽。高速衝擊聚合反應塗層82經塗覆以允許具有防水效能性質之另一高速衝擊聚合反應塗層84黏結至板80及焊柄86。
參考圖5，在本發明之另一實施例中，展示一光柵複合沈積。在此實施例中，用衍生自一種預聚物之APAP高速衝擊聚合反應塗層90處理表面88。第二沈積92並行於且自第一沈積平移。第二沈積92可使用一獨立選定之預聚物以產生APAP高速衝擊聚合反應塗層。
參考圖6，在本發明之另一實施例中，展示層化複合物之沈積。在此實施例中，表面94接收一APAP高速衝擊聚合反應塗層。在一敷作中，形成不平衡複合物。第一敷作物102為衍生自100%第一預聚物之原料之高容量衝擊聚合反應塗層。第二敷作物104具有衍生自第一預聚物與第二預聚物之混合物之原料的高速衝擊聚合反應塗層。在第三敷作物106中，高速衝擊聚合反應塗層衍生自具有100%第二預聚物之原料。現已改質表面性質以容納隨後之層(未圖示)以提供保護塗層及/或諸如化學或生物防護織物表面中之表面性質或提供更耐磨損塗層至下伏APAP高速衝擊聚合反應塗層。
參考圖7及8，展示一預聚物傳遞系統，其中由管112供應離子化氣體進入具有配備噴霧套環118的排放噴嘴116之APAP 114中，該噴霧套環118促進預聚物薄霧128導入高速衝擊聚合反應塗佈材料122中。預聚物材料饋料入噴射器132中，其傳遞該材料至用於產生預聚物薄霧128之噴霧套環118之噴霧噴口133。高速衝擊聚合反應塗佈材料122塗覆於表面126，作為高速衝擊聚合反應塗層124。
可為用於活化及沈積之候選者之表面的實例可包含，但不受限於玻璃材料、層合風擋、用於車的玻璃、玻璃、熔蝕玻璃、具有燒結的玻璃、有色玻璃、矽酸鹽、鋁酸鹽、硼酸鹽、氧化鋯、過渡金屬化合物、鋼、碳酸鹽、生物相容性材料、磷酸鈣礦物質、磷酸四鈣、磷酸二鈣、磷酸三鈣、磷酸一鈣、磷酸一鈣單水合物、羥基磷灰石、層合電路板、環氧樹脂、木材、織物、天然纖維、熱塑性塑膠、熱固性塑膠、具有熔融溫度大於70℃的表面、具有可易受熱損的組份的表面，或其組合。在燒結及有色玻璃中，燒結或色彩可在表面上、分散於表面內，或其組合。具有可易於加熱組份之表面可具有組份，該等組份具有諸如熔融或再結晶溫度小於400℃、350℃、300℃、250℃、200℃、150℃、100℃，或小於100℃之性質。易受熱損之表面的其他指示項可具有小於350℃、300℃、250℃、200℃、150℃、100℃，或小於50℃之使用溫度；或一經受小於200℃、150℃、100℃，或小於50℃的玻璃態化溫度的材料。
若表面或沈積具有大於約10x10－ 6
/℃、15x10－ 6
/℃、20x10－ 6
/℃，或50x10－ 6
/℃之線性熱膨脹係數時，亦可認為表面易受熱損。表面與APAP沈積之間的差異膨脹率可導致由剪切應力所致之不正確尺寸或失效。若表面具有小於400℃、350℃、300℃、250℃，或小於250℃之化學分解溫度時，可進一步認為表面易受熱損。可認為分解為一反應實例，其中材料或在表面材料內之鍵結進行化學裂解。可發生裂解之化學反應的其他實例為諸如燃燒、脫水、脫羧反應、熱解或氧化之反應。
易受熱損之表面可包含用於製造先渠模具及沖模，以及需要修復的物品或保護塗層之彼等表面。另外，表面與所塗覆的熔合材料之間的熱膨脹差異可引起在物品中或固化的APAP所塗覆的材料中之殘餘應力、翹曲物品，及自熱震的破裂。易受熱損之此等表面組份之實例可包含環氧樹脂工具、聚矽氧模具、加工板、塑模板、發泡板、中等密度纖維板、纖維層製品、制模板材、可加工蠟、薄殼工具，及用於快速原型設計之各種材料，諸如雷射光硬化樹脂、層合紙、蠟、木材、發泡聚合物，及燒結陶瓷。
易受熱損之表面亦可為一具有小容積以將過剩熱轉移入其中之薄殼。一典型薄殼可小於25 mm、20 mm、15 mm、10 mm、5 mm、4 mm、3 mm、2 mm或甚至小於1 mm厚。
易受熱損之表面亦可為含有顯著殘餘應力之材料。當曝露於大於50℃、100℃、150℃或200℃及小於400℃、350℃、300℃或250℃之熱度時，此等殘餘應力可全部或部分釋放。結果可為易受熱損之表面之三維變形或翹曲。
電漿聚合產生通常未在正常化學條件下所發現之配置中之聚合物。聚合物可具有高度分支鏈、無規終端鏈，或官能交聯位點。一般缺少規則重複單元。此為當預聚物分子曝露於在電漿中固有之高能電子時，預聚物分子斷裂之結果。反應表明由包含自由基形成、均勻分裂、陽離子低聚合反應，及其組合之若干反應路徑進行。
由在常壓空氣電漿中之反應產生之沈積不同於習知聚合物、寡聚物，及單體。在習知單體、寡聚物，及聚合物中，存在一標準系列之一或多個基本組份單元，亦稱為基體(mer)。當聚合鏈生長時，基本組份單元重複且偶然發生交聯。在電漿聚合物中，基本組份單元可斷裂且產生新的官能基。當其再結合時，一般可存在較高交聯密度、增加存在之分支鏈、無規終端鏈，或其組合。當由主鏈原子數所劃分之交聯數接近一時，交聯密度計算變得更加困難。此可為在電漿聚合物中之情況。交聯密度之相對度量可為玻璃態化溫度相對於習知聚合物之位移。吾人可預期在低度交聯處，玻璃態化溫度之上移為對應於交聯數。在電漿聚合物中，與習知聚合物相比，比例斜率可相對增加約10%、15%，或20%。
可適於由常壓空氣電漿沈積之預聚物包含可汽化之化合物。蒸汽可計量且可與一載氣摻合。氣體之此混合物可導入由一常壓空氣電漿所產生之電漿中。常壓空氣電漿之離子化氣體可選自典型熔接過程的氣體，其包含但不受限於稀有氣體、氧氣、氮氣、氫氣、二氧化碳，及其組合。
用於產生高速衝擊聚合物塗層之預聚物可包含，但不受限於第14族反應性經取代化合物，諸如對應於式Ra
X( 3 － a )
M1
－O－M2
Rb
X( 3 － b )
之彼等反應性經取代化合物，其中R為具有賦予所要特徵之官能基的可水解有機基，X可為鹵素，M為諸如矽之第14族元素，且O為氧；對應於式Rn
MX( 4 － n )
的彼等反應性經取代化合物，其中R可為易水解有機基，M為諸如矽的第14族元素，且X可為鹵素；對應於式R2
MO之彼等反應性經取代化合物，其中R為可水解有機基，M為第14族元素，且O為氧；線性矽氧烷；環狀矽氧烷；甲基丙烯醯基矽烷化合物；苯乙烯基官能矽烷化合物；烷氧基矽烷化合物；醯氧基矽烷化合物；胺基經取代矽烷化合物；六甲基二矽氧烷；四乙氧基矽烷；八甲基三矽氧烷；六甲基環三矽氧烷；八甲基環四矽氧烷；四甲基矽烷；乙烯基甲基矽烷；乙烯基三乙氧基矽烷；乙烯基參(甲氧基乙氧基)矽烷；胺基丙基三乙氧基矽烷；甲基丙烯醯氧基丙基三甲氧基矽烷；縮水甘油氧基丙基三甲氧基矽烷；具有鍵結於分子平面間之矽、氫、碳、氧或氮原子的六甲基二矽氮烷；鹵化有機矽烷化合物；鹵化有機鍺烷化合物；鹵化有機錫化合物；二[雙(三甲基矽烷基)甲基]鍺；二[雙(三甲基矽烷基)胺基]鍺；基於鋁或鈦之有機金屬化合物；或其組合。候選預聚物不需要為液體，且可包含為固體但容易汽化之化合物。候選預聚物亦可包含壓縮入氣缸內，或係低溫液化及藉由增加其溫度以一可控方式汽化之氣體。
在某些實施例中，高速衝擊聚合物塗層之厚度可充分增加以產生一與框架部分之密封件。建置厚度可藉由增加所允許發生之沈積的時間；藉由增加沈積產量；藉由使沈積增容；或其組合來達成。增加沈積時間可涉及，但不受限於保持APAP之位置大體上在相同地點達一段較長時間，或使用多個APAP以橫過該相同位置。
在本發明之另一實施例中，多個APAP可沈積不同預聚物使得產生一層化複合沈積、在不同空間區域之不同預聚物以產生一光柵化複合沈積，或其組合。
本發明之另一實施例涉及使用APAP塗覆作為底塗劑之預聚物。第二層可隨後塗覆至該底塗劑以將底塗劑連接至框架部分。在其中第二層接合一風擋至一框架之非限制性實例中，高速衝擊聚合物塗層之珠粒可為10 mm寬。第二層通常與高速衝擊聚合物塗層同寬或比高速衝擊聚合物塗層寬。第二層可包含，但不受限於CASE化合物、聚胺基甲酸酯化合物、聚醯亞胺化合物、金屬膜、錦綸化合物、清漆、硫化化合物、有機薄膜、抗腐蝕化合物、生物相容性塗層、疏水性塗層、親水性化合物、矽氧烷化合物、錫化合物、鍺化合物、陶瓷燒結、塗料、環氧樹脂，或其組合。CASE化合物包含，但不受限於保護塗層、抗磨損塗層、防蝕控制塗層、塗料、保形塗層、環氧樹脂保護塗層、丙烯酸保護塗層、醇酸保護塗層、聚胺基甲酸酯保護塗層、壓敏性黏接劑、乳液聚合物、聚矽氧、木材防腐劑、熱塑性彈性體、醫用黏接劑、用於織物之塗層、填縫劑、橡膠化合物、粉末塗料、碳黑、輻射硬化化合物，及其組合。
第二層之黏著力可使用Quick Knife Analysis方法分析。根據此方法，表面處理後，CASE化合物之黏接劑珠粒塗覆於表面且允許乾燥三天時間。三天後，用一剃刀對角切割。接著將切片扭轉且牽拉直至其黏著失效、內聚失效，或其組合。報導所得失效模式。
框架可用來保護及/或連接不同材料之一或多個部分至上部系統結構。框架可由任何數量之材料製成，只要該等材料適合設計目的。實例可包含，但不受限於金屬通道或環繞汽車玻璃窗玻璃之聚胺基甲酸酯罩或附著於電路板具有防水塗層之焊料薄片。
APAP清理與活化步驟及高速衝擊聚合反應塗層之沈積發生於一單一步驟中。雖然不希望受限於單一操作理論，表明自噴嘴排放之APAP氣體具有一離子化電漿之半影，其在第一段時間中執行一清理及活化步驟(簡稱為清理)，隨後極其迅速地及在一個步驟中，進行在自噴嘴排放的離子化電漿的核心處所集中的高速衝擊聚合反應塗料的沈積。
在此實例中，配備由Plasma Treat North A merica,Inc.供應的FLUME APAP之機械臂傳遞一衍生自六甲基二矽氧烷(HMDSO)預聚物之高速衝擊聚合反應塗料。大約每小時30公克HMDSO係以每分鐘5 L空氣稀釋。HMDSO與空氣之混合物導入APAP。離子化氣體在每分鐘30 L下導入。當(諸如)在一具有在通道之間的2 mm間距之光柵圖案中，需要定向改變時，用行進速度高達每秒鐘600 mm之機械臂將高速衝擊聚合反應塗料塗覆於一距離排放噴嘴8 mm的玻璃。
在此實例中，清理及活化步驟獨立於高速衝擊聚合反應塗層沈積步驟而發生。在機械臂上之APAP跟蹤以每秒鐘25 mm之機械氣體。如在實例1中，使用相同條件。
在此實例中，配備由Plasma Treat North America,Inc.供應的FLUME APAP之機械臂藉由傳送一電漿於表面上來清理表面。離子化氣體、空氣，以每分鐘30 L導入。當(諸如)在具有在通道之間的2 mm間距之光柵圖案中，需要定向改變時，用行進速度高達每秒鐘600 mm之機械臂將清理電漿塗覆於一距離排放噴嘴8 mm的玻璃。第二APAP沿與清理電漿相同之機械行進路徑且傳遞一衍生自四乙氧基二矽氧烷(TES)預聚物之高速衝擊聚合反應塗層。大約每小時30公克之TES用每分鐘5 L之空氣稀釋。TES與空氣之混合物導入APAP。離子化氣體以每分鐘30 L導入。當(諸如)在具有在通道之間的2 mm間距之光柵圖案中，需要定向改變時，用行進速度高達每秒鐘600 mm之機械臂將高速衝擊聚合反應塗層塗覆於一距離排放噴嘴8 mm的玻璃。
此實例展示使用APAP於一或兩個步驟中清理表面、繼而沈積高速衝擊聚合反應塗層，相對於用APAP簡單清理及活化玻璃、用異丙醇溶劑擦拭物清理玻璃，或單獨將預聚物塗覆至玻璃而言改良第二層對玻璃之黏著力。
展示黏著結果之測試方法為Quick Knife Adhesion方法。處理後，CASE化合物之黏接劑珠粒(在該種狀況下為聚胺基甲酸酯封閉劑)塗覆於表面且允許乾燥三天時間。三天後，用一剃刀對角切割。接著將切片扭轉且牽拉直至珠粒黏著或內聚失效。所要結果為內聚失效。
所使用之表面包含標準汽車玻璃窗風擋玻璃、以已留置曝露於空氣達一年之髒的風擋玻璃形式的熔蝕汽車玻璃窗、具有燒結區的風擋玻璃。
此測試結果報導於表1中。
另外，熔蝕玻璃與曝露於相同熔蝕條件之燒結的組合，在相同沈積條件下，僅在兩步操作中展示內聚失效。
此實例展示層化複合高速衝擊聚合反應塗層之產生。塗覆條件與實例2中之條件相似。
在此實例中，一單獨APAP清理且活化表面。在一機械臂上之第二APAP使用作為預聚物之HMDSO，塗覆一層0.1 μm的高速衝擊聚合反應塗層。在機械臂上之第三APAP沿與第二APAP相同的機械通道且使用作為預聚物之八甲基三矽氧烷塗覆一層0.05 μm的高速衝擊聚合反應塗層。
此實例展示一光柵複合高速衝擊聚合反應塗層之產生。塗覆條件與實例2中之條件相似。
在此實例中，一單獨APAP清理且活化表面。在一機械臂上之第二APAP使用作為預聚物之HMDSO，塗覆一層0.1 μm的高速衝擊聚合反應塗層。在機械臂上之第三APAP沿自第二APAP路徑平移2 mm之機械通道平行路徑且使用作為預聚物之八甲基三矽氧烷塗覆一層0.1 μm的高速衝擊聚合反應塗層。
此實例展示一分級高速衝擊聚合反應塗層之產生。塗覆條件與實例2中之條件相似。
在此實例中，一單獨APAP清理且活化表面。在一機械臂上之第二APAP塗覆一層0.1 μm的高速衝擊聚合反應塗層。預聚物作為一純HMDSO預聚物起始。在與第一敷作相同之機械臂行進路徑上之第二機械敷作期間，第二APAP使用經調整至一HMDSO與八甲基三矽氧烷的等容混合物的預聚物。在與第一敷作相同之機械臂行進路徑上之第三機械敷作期間，第二APAP使用經調整至純化八甲基三矽氧烷的預聚物。
在此實施例中，展示一實施例，其中利用中斷高速衝擊聚合反應塗層之塗覆及/或清理及活化步驟之能力以在表面上產生一遮罩。塗覆條件與實例2中之條件相似。
在此實施例中，在機械臂上之單一APAP清理且活化表面，隨後在0.01秒內沈積一層1 μm的高速衝擊聚合反應塗層。使用預定程式化信號，APAP中斷產生電漿之電離及預聚物流。機械臂繼續行進一段距離。使用第二預定程式化信號，APAP恢復清理及活化步驟及高速衝擊聚合反應塗層之沈積。
0.5秒鐘後，另一機械臂沿APAP所使用之相同機械臂行進路徑塗覆一輻射硬化CASE封閉劑。自APAP之紅外及/或紫外光硬化CASE封閉劑。
在隨後之操作中，用一鋒利工具，在高速衝擊聚合反應塗佈之空間與未塗佈區域之間的界面處切割CASE封閉劑。接著，由於其黏著失效，因此將在未塗佈區域之CASE封閉劑自表面移除乾淨。
此實例展示電漿之操作條件影響高速衝擊聚合反應塗層之組成。在具有排空至0.027 Pa壓力且電漿由40 kg Hertz磁控管產生之電漿腔室的物理蒸汽沈積系統中，注入HMDSO預聚物。生成的聚合反應塗層之化學分析展示19.8%原子之矽含量。
使用在實例2中之條件，當注入HMDSO預聚物時，生成高速衝擊聚合反應塗層經分析具有32.0%之矽含量。使用此技術之塗層可預期具有大於25%之矽含量。
此實例描述對於塗佈速度使用不同參數所達成之表面溫度。在排放噴嘴與表面之間的8 mm距離處，當機械臂以600 mm/s行進時，表面溫度達95℃之最大值。當機械臂以50 mm/s行進時，表面溫度達180℃之最大值。
已詳細描述用於進行本發明之最佳模式，而熟習本發明相關之該項技術者應瞭解多種替代設計及實施例可用於實行如由以下申請專利範圍所定義之本發明。
1．．．汽車
2．．．車體上部系統
4．．．框架
6．．．有色區
8．．．風擋
9．．．側窗
10．．．燒結
11．．．後視鏡
12．．．天窗密封件
13．．．天窗
14．．．彈性壓條
16．．．電子電路板
18．．．輪轂罩
20．．．塑膠儀錶板
22．．．預聚物原料容器
24．．．額外原料容器
26．．．供應線
28．．．供應線
30．．．管
32．．．質量流量控制器、計量設備
34．．．計量表
36．．．原料容器
38．．．混合腔室
40．．．離子化氣體原料容器
42．．．計量表
44．．．常壓空氣電漿裝置
50．．．排放噴嘴
54．．．高速衝擊聚合反應塗佈材料之較高濃度區
56．．．外部半影
58．．．表面
60．．．陶瓷燒結
62．．．高速衝擊聚合反應塗層
64．．．有色玻璃
66．．．框架
68．．．表面
70．．．高速衝擊聚合反應塗層
72．．．CASE化合物
74．．．框架
76．．．光輻射
78．．．APAP
80．．．電子電路板
82．．．高速衝擊聚合反應塗層
84．．．高速衝擊聚合反應塗層
86．．．焊柄
88．．．表面
90．．．APAP高速衝擊聚合反應塗層
92．．．第二沈積
94．．．表面
102．．．第一層
104．．．第二層
106．．．第三層
112．．．管
114．．．APAP
116．．．排放噴嘴
118．．．噴霧套環
122．．．高速衝擊聚合反應塗佈材料
124．．．高速衝擊聚合反應塗層
126．．．表面
128．．．預聚物薄霧
132．．．噴射器
133．．．噴霧噴口
圖1展示一應用本發明某些實施例於一汽車上之實例；圖2展示一沈積高速衝擊聚合反應塗層於本發明某些實施例之表面上之實例；圖3展示沈積高速衝擊聚合反應塗層於本發明某些實施例之表面上之另一實例；圖4展示一本發明某些實施例之具有高速衝擊聚合反應塗層、第二層，及框架之經塗佈的玻璃表面的實例；圖5展示一本發明某些實施例之具有複合高速衝擊聚合反應塗層之經塗佈的玻璃表面的實例；圖6展示一本發明某些實施例之具有複合高速衝擊聚合反應塗層之經塗佈的玻璃表面的實例；圖7展示一根據本發明某些實施例之預聚物傳遞系統之實例；且圖8展示關於線8－－8所獲取之噴霧套環之橫截面。
22．．．預聚物原料容器
24．．．額外原料容器
26．．．供應線
28．．．供應線
30．．．管
32．．．質量流量控制器、計量設備
34．．．計量表
36．．．原料容器
38．．．混合腔室
40．．．離子化氣體原料容器
42．．．計量表
44．．．常壓空氣電漿裝置
50．．．排放噴嘴
54．．．高速衝擊聚合反應塗佈材料之較高濃度區
56．．．外部半影
58．．．表面
60．．．陶瓷燒結
62．．．高速衝擊聚合反應塗層
64．．．有色玻璃
66．．．框架
Claims (20)
- 一種塗佈一表面以用於黏結之方法，該方法包括：(a)在一第一段時間期間，清理一待黏結之表面；且(b)在一第二段時間期間，在環境氣壓下，沈積一高速衝擊聚合物反應塗層於該表面上。
- 如請求項1之方法，其進一步包括(c)在步驟(a)與(b)之間等待一第三段時間，該第三段時間係大於0.001秒鐘及小於5天。
- 如請求項1之方法，其進一步包括(c)內聚地塗覆一第二層至該經塗佈之表面。
- 如請求項1之方法，其進一步包括(c)用一電漿空氣處理再活化該表面。
- 如請求項3之方法，其中該第二層為一選自由塗料、黏接劑、封閉劑、彈性體化合物，及其組合組成之群的材料。
- 如請求項1之方法，其中該待黏結之表面為一玻璃材料，或一用陶瓷玻璃料(frit)所塗佈之玻璃材料。
- 如請求項1之方法，其中在噴嘴處之沈積速度為大於每秒鐘10公尺及小於每秒鐘200公尺。
- 如請求項1之方法，其中該塗層係由一反應性經取代之基於Si之預聚物製造且具有至少25%的矽原子含量。
- 一種塗佈一表面以用於黏結之方法，該方法包括：(a)提供一具有一待黏結表面之基材；(b)導入一預聚物蒸汽至一常壓空氣電漿以形成一聚合物反應化合物；且 (c)用一高速衝擊裝置沈積該聚合物反應化合物至該基材之待黏結表面。
- 如請求項9之方法，其中步驟(a)包含導入該預聚物，作為霧狀物。
- 如請求項9之方法，其中該預聚物為一具有式Ra X(3-a) M1 -O-M2 Rb X(3-b) 之第14族的反應性經取代化合物，其中R為一可水解有機基，X為一鹵素，M為一諸如矽的第14族元素，O為氧，a係從0至3，且b係從0至3，或式Rn MX(4-n) ，其中R為一易水解有機基，M為一諸如矽之第14族元素，X為一鹵素，一實例為四乙氧基矽烷。
- 如請求項11之方法，其中該反應性經取代化合物為六甲基二矽氧烷，且n係從0至4。
- 一種經塗佈玻璃表面，該表面包括：(a)一玻璃表面；及(b)一具有第一及第二相對表面之高速衝擊聚合物反應塗層，該第一相對表面相鄰於該玻璃表面。
- 如請求項13之經塗佈玻璃表面，其進一步包括(c)一相鄰於該高速衝擊聚合物反應塗層之第二相對表面之一部分的框架。
- 如請求項14之經塗佈玻璃表面，其進一步包括：(c)一具有第三及第四相對表面之第二層，其中該第三相對表面相鄰於該高速衝擊聚合物反應塗層的第二相對表面且該第四相對表面相鄰於該框架的一部分。
- 如請求項15之經塗佈玻璃表面，其中該第二層為一選自 由塗料、黏接劑、封閉劑、彈性體化合物，及其組合組成之群的材料。
- 如請求項13之經塗佈玻璃表面，其中該高速衝擊聚合物反應塗層係由一預聚物蒸汽之常壓空氣電漿沈積來塗覆。
- 如請求項17之經塗佈玻璃表面，其中該預聚物為一具有式Ra X(3-a) M1 -O-M2 Rb X(3-b) 之第14族反應性經取代化合物，其中R為一可水解有機基，X為一鹵素，M為一諸如矽的第14族元素，O為氧，a係從0至3，且b係從0至3，或式Rn MX(4-n) ，其中R為一易水解有機基，M為一諸如矽的第14族元素，X為一鹵素，一實例為四乙氧基矽烷，且n係從0至4。
- 如請求項13之經塗佈玻璃表面，其中該玻璃表面為一汽車玻璃表面。
- 如請求項13之經塗佈玻璃表面，其中該塗層為一複合塗層。
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| US20110171426A1 (en) * | 2005-12-27 | 2011-07-14 | Industrial Technology Research Institute | Hard water-repellent structure and method for making the same |
| TWI322833B (en) * | 2005-12-27 | 2010-04-01 | Ind Tech Res Inst | Water-repellent structure and method for making the same |
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| US8048530B2 (en) | 2011-11-01 |
| CN1936073B (zh) | 2012-06-20 |
| US20070065582A1 (en) | 2007-03-22 |
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| GB2430395B (en) | 2011-11-23 |
| US7517561B2 (en) | 2009-04-14 |
| CA2559293C (en) | 2016-02-16 |
| DE102006044347A1 (de) | 2007-03-22 |
| GB2430395A (en) | 2007-03-28 |
| CA2559293A1 (en) | 2007-03-21 |
| GB0616204D0 (en) | 2006-09-27 |
| TW200728227A (en) | 2007-08-01 |
| CN1936073A (zh) | 2007-03-28 |
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