WO2018058718A1 - 一种含油墨图案的曲面玻璃的制备方法 - Google Patents

一种含油墨图案的曲面玻璃的制备方法 Download PDF

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WO2018058718A1
WO2018058718A1 PCT/CN2016/102891 CN2016102891W WO2018058718A1 WO 2018058718 A1 WO2018058718 A1 WO 2018058718A1 CN 2016102891 W CN2016102891 W CN 2016102891W WO 2018058718 A1 WO2018058718 A1 WO 2018058718A1
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film
bending
curved glass
hot bending
mold
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PCT/CN2016/102891
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English (en)
French (fr)
Inventor
周群飞
饶桥兵
黄洋
耿强
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蓝思科技股份有限公司
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Priority to KR1020197011930A priority Critical patent/KR102221933B1/ko
Publication of WO2018058718A1 publication Critical patent/WO2018058718A1/zh

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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
    • B32B1/00—Layered products having a non-planar shape
    • 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
    • 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
    • B32B17/1055—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
    • B32B17/10779—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 containing polyester
    • 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
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • 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
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0007—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality
    • B32B37/003—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality to avoid air inclusion
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0076—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised in that the layers are not bonded on the totality of their surfaces
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B32B37/1009—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure using vacuum and fluid pressure
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B32B37/1018—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure using only vacuum
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0036—Heat treatment
    • B32B38/004—Heat treatment by physically contacting the layers, e.g. by the use of heated platens or rollers
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat

Definitions

  • the invention relates to a method for processing glass, in particular to a method for preparing curved glass containing an ink pattern.
  • the traditional flat glass surface pattern processing process is a flat printing ink pattern onto a flat glass, specifically using silk screen printing, mime printing, pad printing and the like.
  • 3D curved glass can be a glass including a central flat area and four peripheral curved, 3D screen has become a trend and fashion, such as mobile phones, tablets, watches, headphones and other screen panels may use 3D screen, thus the glass surface Printing has also changed from traditional graphic printing to 3D curved printing.
  • the structural characteristics of 3D glass products if 3D curved glass is printed using a conventional glass printing scheme, the printed pattern is not highly accurate on the 3D curved glass, the pattern is not clear, and some places are especially on the 3D curved glass.
  • the curved arc surface and the four corners will have problems such as incomplete printing of ink.
  • Chinese Patent Application No. 201310624893.2 discloses a method for manufacturing a three-dimensional glass film, comprising the steps of: providing a film having a body layer and an adhesive layer (such as polyethylene terephthalate film); placing a stereo glass and film In a hot pressing mold, the adhesive layer is disposed corresponding to the stereoscopic glass; providing at least one of a predetermined temperature (50 ° C to 130 ° C) and a predetermined pressure (1 to 3 atmospheric pressure) to the film to pre-form the film; The hot pressing mold presses the pre-formed film and the stereoscopic glass to make the film and the stereoscopic glass adhere to each other.
  • a predetermined temperature 50 ° C to 130 ° C
  • a predetermined pressure (1 to 3 atmospheric pressure
  • the method enables the film to be flat and evenly bonded to the stereoscopic glass, and can also be applied to a stereoscopic glass having different curved surfaces.
  • the above film further comprises a functional layer, the functional layer comprising an ink layer, a conductive layer, or a combination thereof.
  • this method has a high risk of crushing, and the prepared stereoscopic glass product cannot guarantee that the bonding section of the film and the stereoscopic glass is 100% bubble-free.
  • the invention provides a preparation method of a curved glass containing an ink pattern, comprising the following steps:
  • Step A printing: printing an ink pattern on the film, the film base of the film has a thickness of 40 to 60 microns;
  • Step B film hot bending: the film film obtained in step A is placed in a hot bending mold of a film, and the bending of the hot bending is performed.
  • the temperature is 60-85 ° C
  • the film is formed by hot bending into a film
  • the ink pattern is located on the concave surface and/or the convex surface of the film
  • the size of the film hot bending mold is designed to bend the obtained film.
  • the degree is greater than the curvature of the curved glass to leave a rebound margin for the film;
  • Step C bonding: the convex surface of the film obtained in step B and the concave surface of the curved glass are bonded together using a vacuum bonding apparatus to obtain the curved glass containing the ink pattern.
  • the thickness of the film substrate in the present invention is preferably 40 to 60 ⁇ m.
  • the ink pattern printed in step A is a border area pattern
  • the area size of the printed pattern is larger than the size after cutting.
  • the film-forming temperature is most preferably from 60 to 85 °C. When the mold clamping temperature is greater than 85 ° C, the film is severely contracted by high temperature and severe warpage after hot bending.
  • the film bending mold comprises an upper mold block, and the downward ejection stroke of the upper mold block is 2-8 mm, preferably 3-5 mm, for preparing for film bonding.
  • the mold block presses the film and keeps the film from shifting during the hot bending process, and ensures that the film does not stick to the upper mold and remains on the lower mold after the mold is opened.
  • the step A further includes the step of cutting the film sheet with the ink pattern, and preferably cutting the film to cut the flat surface according to the size of the film obtained after the forming. sheet.
  • the film substrate is a PET film
  • the film comprises a film substrate and an OCA rubber layer covering the film substrate on one side, and the OCA rubber layer has a thickness of 20 to 35 micrometers.
  • the film of the film in the film bending mold is positioned by a plurality of peripheral positioning blocks and vacuum adsorption, and the film is cooled and cooled in the cooling water after the hot bending, and then the mold is taken out to take out the film.
  • the upper mold assembly and the lower mold assembly in the film hot bending mold are clamped and positioned by a plurality of sets of guide columns and guide sleeves.
  • the film is kept in the mold and cooled, and the surface of the film product is cooled. The heat is transferred to the water, the temperature of the film is gradually lowered, the shrinkage is small, and the amount of deformation is small, which satisfies the normal production demand.
  • the film bending temperature of the hot bending in step B is 65-75 ° C
  • the clamping pressure is 500-650 kgf, preferably 520-620 kgf
  • the hot bending time is 90-150 s
  • the cooling time is 20-40 s. .
  • the film of the film obtained by the operation under such parameters does not have the problem of wrinkles of the four corners.
  • the curvature of the film is greater than the curvature of the curved glass, so that the curvature of the film of the film after the hot bending of the film is reduced by 0.2 to 1.0 with respect to the bending curvature of the curved glass.
  • Mm preferably 0.3 to 0.8 mm.
  • the d is the parallel tangential distance between the outer end point of the concave arc on the concave surface of the curved glass to the arc of the convex surface of the film.
  • the cutting method in step A is die cutting or laser cutting
  • the film bending in step B is hydraulically driven.
  • the die is designed according to the size of the film, and the dimensional accuracy of the film after cutting can be guaranteed within ⁇ 0.02 mm tolerance.
  • the dimensional accuracy of the film after cutting is guaranteed to be within ⁇ 0.05 mm.
  • step C the CCD image sensor is used to grasp the bonding reference between the film and the curved glass before the vacuum bonding, and after the two are closely attached in the vacuum bonding device, This includes the process of high pressure defoaming.
  • the PET substrate of the film in step A has a thickness of 50 microns and the film has an OCA film thickness of 25 microns.
  • the flat film film is first formed by hot bending of the mold to form the curved shape of the 3D glass, and the rebound margin of the film is left, and the film is bonded to the 3D curved glass.
  • the invention solves the bubbles in the process of preparing the curved glass containing the ink pattern by separately forming the film, setting the rebound margin of the film, selecting the specific film base thickness and the specific film bending temperature of the film. And other issues.
  • the printing ink material selected by the invention is a high temperature resistant and ductile film.
  • the invention completely overcomes the problems of wrinkles, bubbles and indentations of the film and the glass paste, and the size of the film is stable and the fitting precision is achieved. Well, the film bends and deforms little after hot bending.
  • the temperature of the film bending is low, and the quality of the ink layer printed thereon is not affected by the film bending process.
  • the glass is not bent as a mold for the hot bending of the film after being separately bent at a high temperature of 700 to 800 ° C, and the risk of fracturing of the 3D curved glass is greatly reduced.
  • the invention sets the mold and the hot bending parameters of the film for the hot bending of the film, so that the film is optimally matched with the 3D curved glass after the hot bending.
  • the curved glass surface obtained by the invention has high ink pattern precision and beautiful appearance of the product.
  • the invention has simple process, high reliability, strong operability, easy promotion and application, low cost and high practical value.
  • Fig. 1 is a schematic view showing the position and structure of a film and a curved glass before lamination, wherein 1 is a curved glass and 2 is a film.
  • the flat sheet film of the present invention comprises a film base material and an OCA rubber layer, and a side of the film base material is covered with a "light peeling type film", and the thickness thereof is, for example, 0.05 mm, and the surface is used after the "light peeling type film” is peeled off.
  • the printing ink is coated with a "release film” on the side of the OCA rubber layer, and the thickness thereof is, for example, 0.1 mm. After the "release film” is peeled off, the surface is used for pasting with the curved glass.
  • the film obtained after the hot bending is a structure with a center structure and an arc-edge structure, which is similar to the 3D curved glass structure but has a structure of the film rebound margin.
  • the invention provides a preparation method of a curved glass containing an ink pattern, comprising the following steps:
  • Step A printing and cutting: printing an ink pattern on a film film having a thickness of 40 to 60 ⁇ m (the film thickness of the film substrate in Comparative Examples 1 and 2 is less than 40 ⁇ m), and cutting the ink pattern Film film;
  • Step B Film hot bending: the cut film film is placed in a hot bending mold of the film, and the bending temperature of the hot bending is 60-80 ° C, and the film is formed into a film by hot bending.
  • the ink pattern is located on the concave surface of the film; and the size of the film bending mold is designed such that the curvature of the obtained film is greater than the curvature of the curved glass to leave a rebound margin for the film;
  • Step C bonding: the convex surface of the film obtained in step B and the concave surface of the curved glass are bonded together using a vacuum bonding apparatus to obtain the curved glass containing the ink pattern.
  • step B film hot bending forming process
  • the following operation steps are included, positioning the film ⁇ vacuum adsorption film ⁇ mold clamping hot pressing ⁇ cooling ⁇ opening the mold ⁇ taking out the film.
  • the heating device is turned off between the mold clamping hot pressing step and the cooling step, and the heating device is turned on between the cooling step and the mold opening step.
  • the process parameters are as follows: the product positioning and adsorption time of the hot bend film is 5s, the upper mold temperature change time and the lower mold temperature change time are both 70s, and the cooling water pump flow rate is 50L. /Min.
  • the initial pressure time is 1 s
  • the re-pressing time is 30 s
  • the cooling water pump running time is 35 s
  • the oil pipe pressure before opening the mold is 1205 kgf (gauge pressure)
  • the lower oil pipe pressure is 508 kgf
  • the upper mold temperature is 66.3 ° C.
  • the lower mold temperature was 65.2 ° C
  • the pressure of the upper oil pipe after opening the mold was 1021 kgf
  • the pressure of the lower oil pipe was 464 kgf
  • the temperature of the upper mold was 51.5 ° C
  • the temperature of the lower mold was 53.7 ° C. It takes 5s to take out the product and the hot bending cycle is 120s.
  • the film hot bending process considering that the film has no functional holes and auxiliary positioning features, we adopt the four-side positioning and the upper die pressing block (upper die block) to achieve the precision of the film hot bending forming.
  • the curvature of the film 2 is 0.5 mm with respect to the retracted dimension d of the curved glass 1, and the film formed by the film is similarly reduced by 0.5 mm from the curvature of the 3D glass.
  • the vacuum bonding machine is used to grasp the reference of the film and the 3D curved glass through the CCD, so that the two are closely adhered, and the high-pressure defoaming technology is performed to achieve 3D.
  • the glass surface ink pattern has high precision and beautiful appearance.
  • the defoaming process first remove the bubble with a pressure of 6.5kgf and a temperature of 45 °C. After 15 min, the pressure was 6.5 kgf and the temperature was removed at 25 ° C for 15 min. Finally, the pressure was 6.5 kgf and the temperature was 45 ° C for 3 min.
  • the inventors found through experiments that when the thickness of the film substrate is too high (for example, more than 60 ⁇ m), the film is easily wrinkled after hot bending, and the molding is unstable. According to the experimental results of Table 1, it is known that the thickness of the PET substrate of the film is 40 to 60 ⁇ m, and the thickness of the OCA layer is 20 to 30 ⁇ m. According to the experimental results, SKC brand film (PET substrate 50 ⁇ m + OCA 25 ⁇ m) was finally selected as a film for large-scale application.
  • the invention prints the ink pattern on the film material to be bonded with the curved glass, and the film is separately formed, the rebound margin of the film is set, the thickness of the specific film substrate is selected, and the specific film bending temperature of the film is set.
  • the problems of bubbles, wrinkles, indentations, and fracturing during the bonding process of the curved glass containing the ink pattern are solved.
  • the curved glass surface obtained by the invention has high ink pattern precision and beautiful appearance of the product.

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  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Quality & Reliability (AREA)
  • Thermal Sciences (AREA)
  • Re-Forming, After-Treatment, Cutting And Transporting Of Glass Products (AREA)
  • Laminated Bodies (AREA)
  • Printing Methods (AREA)

Abstract

一种含油墨图案的曲面玻璃的制备方法，包括如下步骤：印刷；菲林热弯；将前一步骤所得的菲林平片放入菲林热弯模具中热弯，热弯的合模温度为60-85℃，该菲林平片热弯成型为菲林曲片；且设计菲林热弯模具的尺寸使得所得的菲林曲片的弯曲度大于该曲面玻璃的弯曲度而给菲林曲片留出回弹余量；以及贴合步骤后得到含油墨图案的曲面玻璃。

Description

一种含油墨图案的曲面玻璃的制备方法 技术领域
本发明涉及玻璃的加工方法，具体涉及一种含油墨图案的曲面玻璃的制备方法。
背景技术
传统平面玻璃表面图案处理的工艺是平面印刷油墨图案到平片玻璃上，具体使用丝印、油印、移印等方法。3D曲面玻璃可以是一种包括中心平板区域和四周边弯曲的玻璃，3D屏幕已经成为一种流行趋势和时尚，如手机、平板电脑、手表、耳机等屏幕面板均可能使用3D屏幕，因而玻璃表面印刷也从传统的平面印刷转变为3D曲面印刷。但由于3D玻璃产品的构造特性，若使用传统的玻璃印刷方案印刷3D曲面玻璃时，印刷出来的图案在3D曲面玻璃上尺寸精度不高，图案不清晰，且有的地方尤其是3D曲面玻璃上的弯曲弧面以及四角处会出现油墨印刷不到位等问题。
中国专利申请201310624893.2公开一种立体玻璃贴膜的制造方法，包括下列步骤：提供一具有一本体层与一黏着层的薄膜(如聚对苯二甲酸乙二酯膜)；将一立体玻璃与薄膜置入一热压模具中，黏着层与立体玻璃对应设置；提供一预定温度(50℃至130℃)及一预定压力(1至3大气压力)至少其中之一于薄膜，使薄膜预成形；以及热压模具压合预成形的薄膜与立体玻璃，使薄膜与立体玻璃相互贴合。该方法使薄膜可以平整且均匀的贴合于立体玻璃，亦可应用于具有不同弧度曲面的立体玻璃。其中上述薄膜还包括功能层，上述功能层包括油墨层、导电层、或其组合。但该方法存在很高的压伤风险，且制备的立体玻璃产品无法保证薄膜与立体玻璃的贴合段100％无气泡。
因此，本领域需要提供一种新的含油墨图案的曲面玻璃的制备方法，具体是一种低压伤风险甚至无压伤风险且附着油墨的薄膜层与立体玻璃间贴合完全无气泡、无四角圆弧褶皱、无压痕的含油墨图案的曲面玻璃制备方法。
发明内容
本发明提供一种含油墨图案的曲面玻璃的制备方法，包括如下步骤：
步骤A、印刷：在菲林平片上印刷油墨图案，所述菲林的菲林基材的厚度为40～60微米；
步骤B、菲林热弯：将步骤A所得的菲林平片放入菲林热弯模具中热弯，热弯的合模 温度为60～85℃，所述菲林平片热弯成型为菲林曲片，油墨图案位于所述菲林曲片的凹面和/或凸面；且设计菲林热弯模具的尺寸使得所得菲林曲片的弯曲度大于所述曲面玻璃的弯曲度而给菲林曲片留出回弹余量；
步骤C、贴合：将步骤B所得菲林曲片的外凸面与曲面玻璃的内凹面使用真空贴合设备贴合，得到所述含油墨图案的曲面玻璃。
本发明步骤A中，菲林基材的厚度过低时，平片热弯后菲林产品的贴合面有褶皱，四角有凸起，且菲林片的延展性一般，不能耐受120～180℃的高温。而菲林基材的厚度过高时，热弯后很容易起皱，成型不稳定。因此，本发明中菲林基材的厚度以40～60微米为宜。在一种具体的实施方式中，步骤A中印刷的油墨图案为边框区图案时，印刷图案的区域尺寸要大于裁切后的尺寸。步骤B中，合膜温度为60～85℃最为合适。合模温度大于85℃时，菲林受高温收缩严重，热弯后产生严重翘曲变形。
在一种具体的实施方式中，所述菲林热弯模具包含上模弹块，所述上模弹块的向下顶出行程为2～8mm，优选3～5mm，用于准备合膜时上模弹块压住菲林和使得菲林在热弯过程中保持不移位，且在开模后确保菲林不会粘至上模而留在下模上。
在一种具体的实施方式中，步骤A中还包括裁切带油墨图案的菲林平片的步骤，优选所述裁切为根据成型后得到的菲林曲片展开成平面的尺寸而裁切菲林平片。
在一种具体的实施方式中，所述菲林基材为PET膜，所述菲林包括菲林基材和单面覆盖菲林基材的OCA胶层，且所述OCA胶层厚度为20～35微米。
在一种具体的实施方式中，所述菲林热弯模具中菲林平片通过多个外周定位块和真空吸附定位，且菲林在热弯后先在冷却水中保压冷却再打开模具取出菲林曲片，所述菲林热弯模具中的上模组件和下模组件通过多组导柱和导套进行合模定位。
如果菲林在热弯后不冷却而直接取出，则因产品热胀冷缩而翘曲变形大，进而影响菲林曲片的成型精度；本发明中，菲林在模具里保压冷却，菲林产品的表面热量传递给水，菲林的温度逐渐变低，其收缩很小，变形量也很小，满足正常的生产需求。
在一种具体的实施方式中，步骤B中热弯的合膜温度为65～75℃，合模压力为500～650kgf，优选520～620kgf，热弯时间为90～150s，冷却时间20～40s。如此参数下操作所得的菲林曲片不会出现四角褶皱的问题。
在一种具体的实施方式中，菲林曲片的弯曲度大于所述曲面玻璃的弯曲度而使得菲林热弯后菲林曲片的弯曲弧度相对于曲面玻璃的弯曲弧度内缩距离d为0.2～1.0mm，优选为 0.3～0.8mm。所述d即为曲面玻璃内凹面上的内凹弧线的外侧端点到所述菲林曲片的外凸面的弧线间的平行切线距离。
在一种具体的实施方式中，步骤A中的裁切方法为刀模模切或激光切割，步骤B中菲林热弯采用液压驱动。在使用刀模模切平片菲林时，刀模根据菲林外形尺寸进行设计，切割后菲林的尺寸精度可保证在±0.02mm公差范围内。在使用激光切割平片菲林时，切割后菲林的尺寸精度可保证在±0.05mm公差范围内。
在一种具体的实施方式中，步骤C中在真空贴合前通过CCD图像传感器抓取菲林曲片与曲面玻璃的贴合基准，且在真空贴合设备中使二者紧密贴合后，还包括对其进行高压除泡的工序。
在一种具体的实施方式中，步骤A中所述菲林的PET基材厚度为50微米，菲林的OCA胶层厚度为25微米。
本发明至少具备如下有益效果：
1、本发明中，先把平片菲林单独通过模具热弯仿形成3D玻璃的弧面形状，且留出菲林的回弹余量，再将菲林曲片与3D曲面玻璃贴合。本发明通过菲林单独成型、设置菲林的回弹余量、选择特定的菲林基材厚度和特定的菲林热弯合模温度等条件解决了含油墨图案的曲面玻璃的制备过程中贴合时的气泡等问题。
2、本发明选择的印刷油墨用材料为耐高温、有延展性的菲林，本发明完全克服了菲林与玻璃粘贴的褶皱、气泡、压痕等问题，且菲林曲片尺寸成型稳定，贴合精度好，热弯后菲林弯曲变形小。
3、本发明中，菲林热弯的温度低，其上印制的油墨层质量不受菲林热弯工序的影响。本发明中，玻璃在700～800℃的高温下单独热弯后并不作为菲林热弯的模具，大幅降低3D曲面玻璃的压裂风险。本发明给菲林热弯设置其单独使用的模具和热弯参数，使得菲林热弯后与3D曲面玻璃实现最佳匹配。
4、本发明得到的曲面玻璃表面油墨图案精度高、产品外观美观。本发明工艺简单，可靠性较高，可操作性强，易于推广应用，成本较低，实用价值高。
附图说明
图1为贴合前菲林曲片和曲面玻璃的位置结构示意图，图中1为曲面玻璃，2为菲林曲片。
具体实施方式
下面通过具体实施方式对本发明作进一步的详细说明。
本发明的平片菲林包括菲林基材和OCA胶层，且在菲林基材一侧覆盖有“轻剥离型膜”，其厚度例如为0.05mm，撕去“轻剥离型膜”后该面用于印刷油墨；而在OCA胶层一侧覆盖有“离型膜”，其厚度例如为0.1mm，撕去“离型膜”后该面用于与曲面玻璃粘贴。
本发明中热弯后得到的菲林曲片为中心为平面结构而四周为弧边结构，与3D曲面玻璃结构相似但留有菲林回弹余量的结构。
实施例1～3和对比例1～2
本发明提供一种含油墨图案的曲面玻璃的制备方法，包括如下步骤：
步骤A、印刷和裁切：在菲林平片上印刷油墨图案，所述菲林的菲林基材的厚度为40～60微米(对比例1和2中菲林基材厚度小于40微米)，裁切带油墨图案的菲林平片；
步骤B、菲林热弯：将裁切后的菲林平片放入菲林热弯模具中热弯，热弯的合模温度为60～80℃，所述菲林平片热弯成型为菲林曲片，油墨图案位于所述菲林曲片的凹面；且设计菲林热弯模具的尺寸使得所得菲林曲片的弯曲度大于所述曲面玻璃的弯曲度而给菲林曲片留出回弹余量；
步骤C、贴合：将步骤B所得菲林曲片的外凸面与曲面玻璃的内凹面使用真空贴合设备贴合，得到所述含油墨图案的曲面玻璃。
具体在步骤B菲林热弯成型过程中，包括如下操作步骤，定位菲林→真空吸附菲林→合模热压→冷却→开模→取出菲林。且在合模热压步骤和冷却步骤之间关闭加热装置，并在冷却步骤和开模步骤之间开启加热装置。在采用四柱液压驱动设备热弯菲林时其工艺参数例如为：热弯菲林的产品定位和吸附时间为5s，上模升温变化时间和下模升温变化时间均为70s，冷却水的水泵流量为50L/Min。热弯过程中初压时间为1s，再压时间为30s，冷却水泵运行时间为35s，开模前的上油管压力为1205kgf(表压)，下油管压力为508kgf，上模温度为66.3℃，下模温度为65.2℃；开模后的上油管压力为1021kgf，下油管压力为464kgf，上模温度为51.5℃，下模温度为53.7℃。取出产品耗时为5s，热弯周期共120s。
菲林热弯过程前，考虑到菲林片没有功能孔以及辅助定位特征，我们对其采取外形四边定位，上模压紧块(上模弹块)压紧的方式实现菲林热弯成型的精度。如图1所示，菲林曲片2的弯曲弧度相对于曲面玻璃1的内缩尺寸d为0.5mm，菲林成型的模具同样地相应比3D玻璃的弧度内缩0.5mm。
在步骤C真空贴合和高压除泡过程中，先使用真空贴合机台通过CCD抓取菲林曲片与3D曲面玻璃的基准，使两者紧密贴合后，进行高压除泡技术从而达到3D玻璃表面油墨图案精度高以及外观美观的效果。除泡过程中，先采用6.5kgf的压力和温度45℃除泡 15min，再采用6.5kgf的压力和温度25℃除泡15min，最后采用6.5kgf的压力和温度45℃除泡3min。
实施例1～3和对比例1～2中考察了不同厚度的菲林基材所得含油墨图案的曲面玻璃的制备方法，具体见表1。
表1
Figure PCTCN2016102891-appb-000001
此外，发明人通过实验发现，菲林基材的厚度过高时(如超过60微米)，菲林热弯后很容易起皱，成型不稳定。结合表1实验结果可知，菲林的PET基材的厚度为40～60微米，且OCA胶层的厚度为20～30微米时效果理想。根据实验结果最终选择SKC品牌的菲林(PET基材50μm+OCA 25μm)作为大规模应用的菲林。
本发明通过将油墨图案印刷在待与曲面玻璃贴合的菲林材料上，且菲林单独成型、设置菲林的回弹余量、选择特定的菲林基材厚度和特定的菲林热弯合模温度等条件解决了含油墨图案的曲面玻璃的制备过程中贴合时的气泡、褶皱、压痕以及压裂等问题。本发明得到的曲面玻璃表面油墨图案精度高、产品外观美观。
以上所述仅为本发明的优选实施例而已，并不用于限制本发明，对于本领域的技术人员来说，本发明可以有各种更改和变化。凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (10)

  1. 一种含油墨图案的曲面玻璃的制备方法，其特征在于，包括如下步骤：
    步骤A、印刷：在菲林平片上印刷油墨图案，所述菲林的菲林基材的厚度为40～60微米；
    步骤B、菲林热弯：将步骤A所得的菲林平片放入菲林热弯模具中热弯，热弯的合模温度为60～85℃，所述菲林平片热弯成型为菲林曲片，油墨图案位于所述菲林曲片的凹面和/或凸面；且设计菲林热弯模具的尺寸使得所得菲林曲片的弯曲度大于所述曲面玻璃的弯曲度而给菲林曲片留出回弹余量；
    步骤C、贴合：将步骤B所得菲林曲片的外凸面与曲面玻璃的内凹面使用真空贴合设备贴合，得到所述含油墨图案的曲面玻璃。
  2. 根据权利要求1所述制备方法，其特征在于，所述菲林热弯模具包含上模弹块，所述上模弹块的向下顶出行程为2～8mm，优选3～5mm，用于准备合膜时上模弹块压住菲林和使得菲林在热弯过程中保持不移位，且在开模后确保菲林不会粘至上模而留在下模上。
  3. 根据权利要求1所述制备方法，其特征在于，步骤A中还包括裁切带油墨图案的菲林平片的步骤，优选所述裁切为根据成型后得到的菲林曲片展开成平面的尺寸而裁切菲林平片。
  4. 根据权利要求1所述制备方法，其特征在于，所述菲林基材为PET膜，所述菲林包括菲林基材和单面覆盖菲林基材的OCA胶层，且所述OCA胶层厚度为20～35微米。
  5. 根据权利要求1所述制备方法，其特征在于，所述菲林热弯模具中菲林平片通过多个外周定位块和真空吸附定位，且菲林在热弯后先在冷却水中保压冷却再打开模具取出菲林曲片，所述菲林热弯模具中的上模组件和下模组件通过多组导柱和导套进行合模定位。
  6. 根据权利要求1所述制备方法，其特征在于，步骤B中热弯的合膜温度为65～75℃，合模压力为500～650kgf，优选520～620kgf，热弯时间为90～150s，冷却时间20～40s。
  7. 根据权利要求1～6中任意一项所述制备方法，其特征在于，菲林曲片的弯曲度大于所述曲面玻璃的弯曲度而使得菲林热弯后菲林曲片的弯曲弧度相对于曲面玻璃的弯曲弧度内缩距离d为0.2～1.0mm，优选为0.3～0.8mm。
  8. 根据权利要求3所述制备方法，其特征在于，步骤A中的裁切方法为刀模模切或 激光切割，步骤B中菲林热弯采用液压驱动。
  9. 根据权利要求1～8中任意一项所述制备方法，其特征在于，步骤C中在真空贴合前通过CCD图像传感器抓取菲林曲片与曲面玻璃的贴合基准，且在真空贴合设备中使二者紧密贴合后，还包括对其进行高压除泡的工序。
  10. 根据权利要求1～9中任意一项所述制备方法，其特征在于，步骤A中所述菲林的PET基材厚度为50微米，菲林的OCA胶层厚度为25微米。
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