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CN114616097B - 在经化学强化的薄玻璃上设有低辐射镀膜的夹层玻璃及其制备方法 - Google Patents

在经化学强化的薄玻璃上设有低辐射镀膜的夹层玻璃及其制备方法 Download PDF

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Publication number
CN114616097B
CN114616097B CN202080076466.3A CN202080076466A CN114616097B CN 114616097 B CN114616097 B CN 114616097B CN 202080076466 A CN202080076466 A CN 202080076466A CN 114616097 B CN114616097 B CN 114616097B
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China
Prior art keywords
glass
layer
coating
msvd
laminated glass
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CN202080076466.3A
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CN114616097A (zh
Inventor
马里奥·阿图罗·曼海姆·阿斯塔特
王钊宇
何塞·努涅斯-雷格罗
伊万·科内乔
马西莫·米切蒂
艾伦·德·奥利维拉
爱德华多·D.·蒂莫什
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AGP America SA
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AGP America SA
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Abstract

本发明提供了一种汽车夹层玻璃，包括玻璃外层和玻璃内层，所述玻璃外层具有第一表面和第二表面，所述玻璃内层具有第三表面和第四表面。所述玻璃内层的厚度不超过1.0毫米，并经过化学强化。所述第四表面具有低辐射镀膜，可通过对厚度不超过1.0毫米的平板玻璃进行化学强化，然后设置低辐射镀膜，最后将平板玻璃层与形成外层的弧形玻璃层贴合，从而冷弯所述平板玻璃层而获得。

Description

在经化学强化的薄玻璃上设有低辐射镀膜的夹层玻璃及其制 备方法
技术领域
本申请涉及轻质的镀膜夹层玻璃领域。
背景技术
为了应对提高汽车燃油效率的法规要求，以及公众对环保产品日益增长的认识和需求，世界各地的车辆原装设备制造商都在努力提高车辆的能源效率。
为了提高能源效率，这些制造商采用的战略的关键因素之一是轻量化概念。如今，传统且成本较低的材料和工艺正逐渐被创新性的新材料和工艺所取代。这些新材料和工艺虽然有时价格较高，但由于其重量较轻，相应地提高了燃料效率，因此相较于传统材料和工艺仍然得以更广泛的应用。一些新材料和工艺除了有重量较轻的优势，还带来了更多的功能。车辆玻璃也不例外。
车辆的玻璃面积一直在稳步增加，并且在这个过程中一些更重的材料被取代。如今很流行的大型玻璃全景车顶和全景式挡风玻璃只是这种趋势的一个例子。全景式挡风玻璃是一种挡风玻璃，其顶部边缘被大大延长，从而包括了车顶的一部分。全景车顶是一种车顶玻璃，它包括车顶的大部分区域，至少包括车辆的前部和后部座位区的一部分。全景车顶可以由多个玻璃片组成，可以是层压的，也可以是整体的。
减轻车辆重量可以大大改善能源消耗，这对于电动车辆来说尤其重要。这一改善能够直接转化为续航能力的提高，因此成为了消费者关注的关键问题(续航焦虑)。
多年来，标准的车辆挡风玻璃的厚度为5.4毫米。近些年我们看到该厚度已经降到了4.75毫米。虽然0.65毫米的厚度降低似乎意义不大，但以典型的标准钠钙浮法玻璃每立方米2600公斤的密度来计算，厚度每降低1毫米，每平方米的重量就减少2.6公斤。典型的1.2平方米的挡风玻璃从5.4毫米减到4.75毫米，重量就减少了至少2公斤。在一辆总共有6平方米玻璃的车辆上，将所有车窗的厚度减少1毫米，相当于节省了15.6公斤的重量。
然而，如果使用退火钠钙玻璃，玻璃的厚度是有限制的。风荷载作用下的应力一直是一个因素，特别是随着挡风玻璃尺寸的增加，风荷载的问题更加令人担忧。玻璃正在成为越来越多的车辆的结构元素，其对车辆的刚度和强度有很大的贡献。固定式玻璃，一旦用相对柔软的固化聚氨脂粘合后，就会被装上更高模量的粘合剂。因此，曾经被橡胶垫圈和软质丁基胶粘剂隔离的玻璃现在更容易受到来自路面颠簸和车辆扭转的负荷。
如今，外层为2.1毫米、内层为1.6毫米、塑料粘合层(夹层)为0.76毫米的挡风玻璃，其总厚度略低于4.5毫米。这种挡风玻璃正成为一种常见材料，但是这种厚度可能已经到达了传统退火钠钙玻璃的极限。
已知的是，对玻璃层进行化学强化后，可以实现用更薄的玻璃层代替内部玻璃层。化学强化通过使用离子交换过程在玻璃表面形成压缩层来增加玻璃的强度，与热强化类似。两者相比一个重要的区别是，极薄的玻璃也可以进行化学强化，而通过热强化工艺可以达到更高的压缩水平。
标准外层玻璃与薄的化学强化内层玻璃相结合的混合夹层玻璃可以产生比传统层压挡风玻璃更薄更轻的夹层玻璃，而且令人惊讶的是，这种夹层玻璃更加耐用且更耐破损。
汽车设计师面临的另一个挑战是为高效内燃机(ICE)和电动车辆的车厢加热。
典型的内燃机驱动的车辆在将燃料的能量转化为动能方面不是非常有效，因为一些能量被转化为热量。长期以来，管理废热一直是这种车辆设计中面临的主要挑战之一。这种低效的好处之一是：提供了现成的、基本上是免费的动力源，用于加热车厢。典型的内燃机车辆配备了空气/冷却液热交换器，其容量为4000瓦或更大。
随着内燃机车辆效率的提高，一些高效率的小排量发动机汽车，在世界气候寒冷的地区销售，其包括电阻式加热元件以提供足够的客舱热量。电阻式电加热是所有电动车辆唯一可行的选择，因为电池产生的废热非常少。
在电动车辆中，由于客舱加热系统的需求，寒冷的天气会大大减少航程。因此，客舱的隔热变得越来越重要，特别是随着车厢玻璃面积的增加，热损失也会增加。这对司机和乘客的舒适度也很重要，特别是当低温的玻璃车顶位于头顶或其他玻璃部分接近暴露的皮肤时。
热能通过玻璃以对流的方式转移到空气中，并由玻璃表面辐射出来。辐射率是衡量一个表面将辐射多少能量的标准。辐射率被量化为一个物体发射的热量与一个完美黑体的热量之比。标准的透明钠钙玻璃的辐射率为0.84，即辐射84％吸收的热量，使其成为一个糟糕的绝缘体。因此，用钠钙玻璃制成的窗户具有很差的热性能。为了改善热性能，行业中设计了一些镀膜，以降低玻璃表面的辐射率。这些被称为low-e(低发射率)的镀膜，大大减少了热辐射热能的发射量。这种发射的能量是窗户传热的主要组成部分。众所周知，低辐射镀膜的发射率低至0.04，只发射出4％的能量并反射回96％的能量。降低玻璃表面的发射率可以大大改善其绝缘性能。
提高客舱的隔热性能，可以减少在寒冷天气下加热客舱所需的能耗。内部玻璃表面的低辐射镀膜有助于提升客舱的隔热性能。目前，已有一些大型的全景玻璃屋顶被生产，在其内部朝向表面上设有低辐射镀膜，然而这些都是使用传统的标准厚度的热弯曲镀膜平板玻璃制作的。
专利申请US 2015/0070755 A1公开了一种基于ITO的低辐射率镀膜玻璃，用于车辆玻璃的太阳能控制和节能。专利申请US8524337B2公开了另一种基于ITO的玻璃镀膜层，用于中空玻璃单元、VIG单元、冰箱/冰柜、车窗或挡风玻璃的防冷凝应用。
虽然将轻质玻璃与低辐射镀膜相结合是可取的，但选择却很有限。低辐射镀膜的玻璃不能随后进行化学强化，而化学强化的玻璃不能进行热成型。另一方面，热成型的弯曲玻璃不能有效地涂上低辐射镀膜。
因此，相关技术中还没有公开任何带有化学强化玻璃和设于玻璃内表面的低辐射镀膜的轻质夹层玻璃。这样的组合将是非常有价值的。
发明内容
本发明克服了这些限制，在平板玻璃经过化学强化后再镀上低辐射镀膜，然后将镀有镀膜的平板玻璃冷弯到最终形状。
生产这种夹层玻璃的方法的基本步骤在图2中显示。该方法被简化为必须执行的基本步骤，并按规定的顺序进行。非必要的和可选的步骤没有显示出来。常见生产夹层玻璃的方法中固有的而不是发明中特有的步骤没有包括在内。这些步骤包括但不限于切割、研磨、钻孔、粘合、印刷和清洗。这些步骤必须按顺序进行，但也可以在所示步骤之间插入未显示的其他步骤。
可以使用各种手段来生产玻璃外层，图2中没有显示。可以采用本领域已知的任何方便的方法，因此这些步骤没有包括在内，也没有被声明保护。用于玻璃外层的平板玻璃通常被切割，进行边缘加工，然后清洗以去除切割油、碎屑和污染物。
通常情况下，需要设置遮蔽物。最常见的是在玻璃外层201的表面二102上打印黑色熔块(如图1A所示)，然后玻璃将被热弯曲。外玻璃层201可以进行退火处理，热强化或化学强化。
印制的遮蔽物会阻碍离子交换过程，因此，如果需要在玻璃内层202上设置遮蔽物，必须在离子交换过程之后进行。根据所使用的方法，遮蔽物可以在设置低辐射镀膜之前或之后设置。
玻璃内层的典型基材是厚度小于等于1.0毫米的氧化铝硅酸盐玻璃。这种类型的玻璃可以通过化学强化达到非常高的表面压缩程度。钠钙和其他类型的玻璃，当其厚度小于等于1.0毫米时也可以使用。
生产方法如下。
1.对玻璃内层202进行加工，准备进行离子交换化学强化处理。
2.玻璃内层202被化学强化。
3.化学强化后的玻璃在玻璃内层202的内部朝向表面四104上设置低辐射镀膜。
4.在化学强化后，平坦的玻璃内层202与夹层玻璃的其他层组装在一起，并在层压过程中冷弯至最终形状。
值得注意的是，本发明必须至少有两层玻璃，但可以有两层以上而不偏离本发明的本意。
一个额外的且可选的步骤是，除了低辐射镀膜外，还可以应用其他镀膜。这些包括但不限于防指纹(AF)和/或抗反射(AR)镀膜。根据镀膜的类型，这些镀膜可以在设置低辐射镀膜的同时和/或之后的层压过程的之前或期间设置。
通过这种方法，可以生产出一种轻薄的夹层玻璃，由于在内表面应用了低辐射镀膜，因此具有良好的热性能。
优点：
-重量更轻
-增加舒适度
-优异的热性能
-提高效率
-改进的范围
-内部加热和冷却所需的能量更少
-可在表面二上与其他镀膜结合
-可与高性能薄膜和夹层结合
-可与防指纹镀膜结合
-可与防眩光镀膜结合
-可与红外线反射镀膜结合
-可与高性能薄膜结合
-可与高性能夹层结合
附图说明
图1A示出一种典型的车辆夹层玻璃的截面视图。
图1B示出一种带有镀膜和性能薄膜的典型车辆夹层玻璃的截面视图。
图2示出一种方法的步骤流程图。
图3示出一种使用所述方法生产的夹层玻璃的爆炸图。
图4示出一种镀膜的截面视图。
附图标记
2 玻璃
4 粘合/胶合层(夹层)
6 遮盖物
12 薄膜
18 红外反射镀膜
19 镀膜(Low-e,AR,AF)
21 层1
22 层2
23 层3
24 层4
25 层5
26 层6
27 层7
32 化学回火玻璃
44 导电薄膜
44 薄膜
101 表面一
102 表面二
103 表面三
104 表面四
201 外层
202 内层
本发明详细描述
以下用术语来描述本发明的夹层玻璃。
玻璃是一种由至少一层透明材料组成的物品，其作用是提供光线的传输和/或向观看者对面的一面提供视野。它被安装在建筑物、车辆、墙壁或屋顶或其他框架构件或外壳的开口中。
图1A和1B中示出了典型的车辆夹层玻璃的截面视图。所述夹层玻璃由两层玻璃2组成，即玻璃外部或外层201和玻璃内部或内层202。它们通过塑料层4(夹层)永久地粘合在一起。在夹层玻璃中，位于车辆外部的玻璃表面被称为表面一101。与玻璃外层201相对的一面是表面二102。位于车辆内部的玻璃表面是指表面四104。与玻璃内层202的相对的一面为表面三103。表面二102和表面三103由塑料层4粘合在一起。还可以在玻璃上添加遮蔽物6。遮蔽物通常是由印在表面二102或表面四104中的一个或多个之上的黑色搪瓷熔块组成。所述夹层玻璃还可以包括在一个或多个上述表面上的镀膜18。所述夹层玻璃还可以包括在至少两个塑料层4之间层压的薄膜12。
术语“玻璃”可适用于许多有机和无机材料，包括许多不透明的材料。本文中将只提及非有机透明玻璃。从科学的角度来看，玻璃被定义为一种物质状态，包括一种非结晶的无定形固体，其缺乏真正固体的有序分子结构。玻璃具有晶体的机械硬度和液体的随机结构。
玻璃是通过将各种物质混合在一起，然后加热到一定的温度，使它们相互融化并完全溶解，形成可混溶的均质流体而形成的。
可以使用的玻璃类型包括但不限于：典型的汽车玻璃的常见钠钙类别，以及铝硅酸盐、铝硅酸锂、硼硅酸盐、玻璃陶瓷和其他各种无机固体非晶组合物。这些组合物经过玻璃化后被归类为玻璃，包括不透明玻璃。玻璃层可以由吸热玻璃组合物以及红外反射和其他类型的镀膜组成。
大多数用于容器和窗户的玻璃是钠钙玻璃。钠钙玻璃是由碳酸钠(苏打)、石灰(碳酸钙)、白云石、二氧化硅(硅石)、氧化铝(铝)以及为改变颜色和其他特性而添加的少量物质制成的。
硼硅酸盐玻璃是一种含有氧化硼的玻璃，具有较低的热膨胀系数和较高的抗腐蚀性。它通常用于制造灯泡、实验室玻璃器皿和烹饪用具。
铝硅酸盐玻璃是用氧化铝制成的，比硼硅酸盐玻璃更耐化学品，而且可以承受更高的温度。化学强化的铝硅酸盐玻璃被广泛用于智能手机和其他电子设备的显示屏。
锂-铝硅酸盐是一种玻璃陶瓷，具有非常低的热膨胀和高光学透明度，通常含有3％-6％的Li2O。它通常用于壁炉窗、灶台面板、镜片和其他需要低热膨胀的应用。
玻璃层可以经退火或强化处理。有两种工艺可以用来提高玻璃的强度。一种是热强化，即快速冷却(淬火)热玻璃。另一种是化学强化，通过离子交换化学处理达到同样的效果。
热强化的全钢化钠钙浮法玻璃，抗压强度至少在70Mpa以上，可用于除挡风玻璃以外的所有车辆的位置。热强化玻璃在玻璃的外表面一高压缩性的玻璃层，与玻璃内部的张力相平衡。所述张力由热软化玻璃的快速冷却产生的。当强化玻璃破裂时，拉伸和压缩不再平衡，玻璃会破裂成边缘钝化的小颗粒。强化玻璃的强度比退火的夹层玻璃要强得多。由于所需要的快速传热，典型的车辆热强化工艺的厚度限制在3.2毫米到3.6毫米之间。使用典型的鼓风机式低压空气淬火系统无法实现较薄玻璃所需的高表面压缩。
在化学强化过程中，玻璃外表面及附近的离子与较大的离子进行交换这些离子交换会使玻璃外层处于压缩状态，抗压强度可达到1000Mpa。典型的方法是将玻璃浸没在熔盐罐中从而进行离子交换。玻璃表面不能有任何会干扰离子交换过程的油漆或镀膜。
用于提高玻璃的性能和特性的各种镀膜在如今很易获得并被普遍使用。这些功能包括但不限于：低发射率、红外线反射、防反射、疏水、亲水、自愈、自洁、抗菌、防刮、防涂鸦、防指纹和防眩光。
镀膜应用的方法包括磁控溅射真空沉积(MSVD)以及其他本领域内已知的通过热解、喷雾、可控气相沉积(CVD)、浸渍、溶胶-凝胶和其他方法来应用。
玻璃层采用重力弯曲、压弯、冷弯或本领域已知的任何其他常规手段形成。在重力弯曲过程中，玻璃平板被支撑在玻璃边缘附近，然后被加热。热玻璃在重力作用下下垂至所需形状。在压弯过程中，平板玻璃被加热，然后在整个部分表面模具上进行弯曲。空气压力和真空通常用来协助弯曲过程。用于成型玻璃的重力和压弯方法在本领域是众所周知的，在本发明中将不作详细讨论。
冷弯法是一种相对较新的技术。顾名思义，玻璃在冷的情况下弯曲成最终形状，而不需要使用热量。在曲率最小的部件上，可以将平板玻璃冷弯到部件的轮廓。这是因为随着玻璃厚度的减少，玻璃片的弹性越来越大，可以在不引起足够高的应力水平情况下进行弯曲。高应力水平可以显著增加断裂的长期可能性。退火的钠钙玻璃薄片，厚度约为1毫米，可以弯曲成大半径(大于6米)的圆柱形。当玻璃经过化学或热强化后，玻璃可以承受更高的应力，并可以沿两个主轴弯曲。该工艺主要用于将化学强化的薄玻璃片(<＝1毫米)弯曲成型。
形成的圆柱形的单方向半径可以小于4米。形成的复合弯曲的形状，即两个主轴方向的曲面，每个方向的曲率半径小至约8米。当然，这在很大程度上取决于部件的表面积以及基材的类型和厚度。
冷弯玻璃会一直处于拉伸状态，容易使与之粘合的弯曲层的形状发生扭曲。因此，必须对弯曲层进行补偿以抵消张力。对于曲率较高的复杂形状，可能需要在冷弯前对平板玻璃进行部分热弯。
将待冷弯曲的玻璃放置在弯曲的玻璃层上，并在待冷弯曲的玻璃和弯曲的玻璃层之间放置粘接层。该组件被放置在一个真空袋中。真空袋是一组不透气的塑料片，将组件包围起来，并将塑料片边缘粘合在一起。使空气从组件中排空，同时也对组件施加压力迫使各层接触。之后将抽空的真空袋中的组件加热以密封组件。接下来，组件被放置到高压釜中，加热组件并施加高压。这就完成了冷弯过程，因为此时的平板玻璃已经符合弯曲层的形状，并被永久地贴上了。冷弯工艺与标准的真空袋/高压釜工艺非常相似，只是后者在玻璃堆栈中加入了一个未弯曲的玻璃层，这在本领域是众所周知的。
塑料粘合层4(夹层)的主要功能是将相邻层的主要面相互粘合。选择的材料通常是透明的热固性塑料。
用于车辆时，最常用的粘合层4(夹层)是聚乙烯醇缩丁醛(PVB)。PVB对玻璃有很好的附着力，而且一旦贴合，就会在视觉上保持透明。PVB是由聚乙烯醇和正丁醛反应产生的。PVB是透明的，对玻璃有很高的粘附力。然而，PVB韧性不足，必须添加增塑剂以使该材料具有弹性，并使其能够在汽车所需的广泛温度范围内消散能量。只有少数增塑剂可以被使用，它们通常是线性二羧酸酯。两个常用的增塑剂是己二酸二正己酯和二正庚酸四乙二醇酯。典型的汽车PVB夹层是由30％-40％的增塑剂(按重量计算)组成的。
除了聚乙烯丁醛，还可以使用离子聚合物、乙烯-醋酸乙烯(EVA)、原位浇注(CIP)液体树脂和热塑性聚氨酯(TPU)。车用塑料夹层是由具有一定厚度公差和工艺变化的挤压工艺制成的塑料夹层。由于光滑的表面往往会粘在玻璃上，使其难以在玻璃上定位并滞留空气。所以塑料表面通常进行压花处理，以方便处理塑料片材并从夹层玻璃中去除空气(脱气)。然而，这一过程会导致片材的额外变化。车用PVB夹层的标准厚度为0.38毫米和0.76毫米(15密耳和30密耳)。
除了将玻璃层粘合在一起之外，还可以使用具有增强能力的夹层。本发明可包括旨在抑制声音的夹层。这种夹层整体或部分由一层比常用塑料层更软、更有弹性的塑料层组成。该夹层也可以是具有太阳能衰减特性的类型。
一般来说，夹层玻璃是由多片薄材料组成的物品。相对于它们的长度和宽度而言，每片薄材料都有两个相对布置的主要面，通常厚度相对均匀。它们在各自的至少一个主要面上被永久地粘合在一起。
如图1所示，夹层安全玻璃是通过使用由透明热塑性塑料4的薄片(夹层)组成的塑料粘合层将两片退火玻璃2粘合在一起制成的。
退火玻璃是已经从弯曲温度通过玻璃化转变范围缓慢冷却的玻璃。这个过程可以消除玻璃在弯曲过程中留下的应力。退火后的玻璃可破碎成带有锋利边缘的大碎片。当夹层玻璃破碎时，碎裂的玻璃碎片就像拼图一样，被塑料层固定在一起，以保持玻璃的结构完整性。挡风玻璃已经破碎的车辆仍然可以进行操作。塑料层4还有助于防止物体从外部击穿夹层玻璃，在发生碰撞的情况下加强了对乘员的支持。有各种各样的薄膜可以被设置在夹层玻璃中。这些薄膜的用途包括但不限于：太阳能控制、可变透光率、增加刚度、增加结构完整性、提高抗穿透性、加强对乘员的支撑、提供屏障、着色、提供遮阳、颜色校正，以及作为功能性和美学图形的基材。术语“薄膜”应包括上述枚举以及可能开发的或目前可用的其他产品，它们可以提高夹层玻璃的性能、功能、美学或成本。大多数薄膜不具有粘性。为了整合到夹层玻璃中，薄膜的每一面都需要有片状塑料夹层，以便将薄膜与夹层玻璃的其他层粘合在一起。
汽车玻璃经常使用吸热玻璃组合物，以减少车辆上的太阳能负荷。虽然吸热窗可能是有效的，但玻璃会发热，并通过对流传输和辐射将能量转移到客舱中。一个更有效的方法是将热量反射回大气层，使玻璃保持低温。这是用各种红外线反射膜和镀膜来实现的。红外线镀膜和薄膜通常太软，无法安装或应用到暴露在空气中的玻璃表面。相反，它们必须被制作成夹层产品的内部层之一，以防止薄膜或镀膜的损坏和退化。
与强化的整体玻璃相比，夹层窗的一大优势是，除了吸热成分和夹层外，还可以利用红外线反射镀膜和薄膜。
红外线反射镀膜18包括但不限于通过磁控溅射真空沉积(MSVD)应用的各种金属/介质分层镀膜，以及通过热解、喷雾、可控气相沉积(CVD)、浸渍和其他方法应用的本领域中已知的其他镀膜。
红外线反射膜包括：金属镀膜的塑料基底以及有机的非金属光学膜，它们可以在红外线下反射。大多数的红外反射膜都是由塑料薄膜基材组成的，上面涂有红外反射的分层金属镀膜。
许多汽车玻璃上的黑色熔块印刷的遮蔽物既具有特定功能，也起到美学作用。玻璃上基本不透明的黑色印刷物的作用是保护用于将玻璃粘合到汽车上的聚氨酯胶粘剂不受紫外线和它可能导致的降解的影响。它还起到了从车辆外部隐藏粘合剂的作用。黑色遮蔽物必须是耐用的，在所有的暴露和天气条件下都能维持车辆的使用寿命。美学要求的一部分是黑色具有深色光泽的外观，并且在不同的部件和时间上具有一致的外观。现今生产的部件必须与20年前生产和使用的部件相匹配。这些部件还必须与车辆上的其他部件相匹配，这些部件可能不是由同一个制造商制造的，也不是用同样的熔块配方制造的。标准的车用黑色搪瓷油墨(熔块)已经被开发出来，可以满足这些要求。
当黑色熔块不实用时，有时会使用其他方法来提供遮蔽，例如当片材将被化学强化，或表面已被镀上与印刷过程不相容的镀膜时。这些包括但不限于有机油墨、底漆和插入物。
热能通过玻璃传递的方式是对流传递或由玻璃表面辐射出来的。辐射率是衡量一个表面将辐射多少能量的标准。辐射率被量化为一个物体发射的热量与一个完美黑体的热量之比。完美黑体的辐射率为1，而完美反射体的辐射率为0。标准的透明钠钙玻璃的辐射率为0.84，辐射84％的热量，使其成为一个糟糕的绝缘体。因此，用钠钙玻璃制成的窗户具有较差的热性能。为了改善热性能，行业中设计了一些镀膜，以降低玻璃表面的辐射率。这些被称为低辐射的镀膜，大大减少了热辐射热能的发射量。这种发射的能量是窗户传热的主要组成部分。降低玻璃表面的辐射率可以大大改善其绝缘性能。众所周知，低辐射镀膜的发射率低至0.04，只发射出4％的能量并反射回96％的能量。低辐射镀膜通常具有在镀膜基材一侧反射红外线的特性，通过减少来自外部的能量传递进一步改善热性能。当试图冷却室内时，这是一个理想的特性。
虽然可以采用一些方法来应用本发明的低辐射镀膜，但已经发现使用双极脉冲直流电源的磁控溅射真空沉积(MSVD)镀膜机可以生产出均匀性更好、导电性更高的镀膜。
一些类型的低辐射镀膜通过热活化过程得到了增强。在这个过程中，被涂覆的基材被加热到一定温度，并保持足够的时间，使镀膜发生某些变化，进一步提高镀膜的热性能。根据所应用的低辐射镀膜的类型，这一可选的步骤可以执行。
沉积在基材32上的第一层应被称为层1。后续的层应以1递增，其顺序如图4所示。玻璃基材32上显示的是五层镀膜堆栈19。
需要注意的是，在化学公式中，任何需要特定化合物的下标都将使用精确的数字。使用一个变量，如x或y，表示声称的化合物包括该变量的所有可能的值。如果使用公式HxO，那么化合物HO和H2O都被要求。由于MSVD和其他镀膜的沉积方式，通常会有多种化合物被形成。
具体实施方式
图3和图4说明了由所述方法的各种实施例生产的所有物品。所示的夹层玻璃是一个1.2米乘1.6米的全景夹层车顶。外层玻璃201是热弯曲的2.1毫米厚的深太阳光绿色的钠钙玻璃。在外玻璃层201的表面二102上印制并烧制了一个黑色的熔块遮蔽物6。内层玻璃202是1.0毫米厚的氧化铝硅酸盐玻璃，通过离子交换过程进行了化学强化。弯曲的外玻璃层201和平坦的内玻璃层202用0.76毫米的深灰色色调的PVB层层压。低辐射镀膜在离子交换后通过磁控溅射真空沉积镀膜机应用于表面四104。该夹层玻璃的总可见光透射率低于5％。
实施例1
1.在实施例1的方法中，钠钙外层玻璃被切割，切割后的玻璃边缘被金刚砂轮研磨成光滑的表面，然后对玻璃进行清洗。在玻璃外层201的表面二102上丝网印刷黑色的熔块遮蔽物6。使用全表面压弯工艺，将玻璃加热并压弯成形，并进行退火处理。
2.内层玻璃202，一种1.0毫米的透明氧化铝硅酸盐玻璃，通过飞秒激光器切割，且不需要进行边缘加工。切割后的玻璃被清洗并准备用于离子交换过程。
3.当准备好足够数量的层后，通过离子交换过程对其进行处理。在离子交换之后，玻璃被准备用于镀膜，再次清洗玻璃以去除盐浴的任何残留物。
4.玻璃通过MSVD镀膜机，将三层低辐射镀膜涂在将成为夹层玻璃表面的表面四104。
层1：SiNx 21
层2：ITO(氧化铟锡)22
层3：SiNx 23
5.镀膜玻璃现在已准备好进行层压。一张PVB 4被放在两层之间，弯曲的玻璃外层201和平坦的玻璃内层202通过真空通道连接在一起。空气被抽空，将表面拉在一起，并将薄的平坦玻璃内层202弯曲到外玻璃层201的轮廓上。随后通过加热、真空和压力处理，将两层玻璃永久地粘合在一起。
实施例2
实施例2与实施例1相似，区别在于低辐射镀膜。MSVD镀膜堆栈由以下组成。
层1：SiOyNx 21
层2：ITO(氧化铟锡)22
层3：SiOyNx 23
实施例3
实施例3与实施例1相似，区别在于MSVD低辐射镀膜上增加了两层抗反射MSVD镀膜，抗反射堆栈的组成如下。
层4：低折射率 24
层5：高折射率 25
实施例4
实施例4与实施例2相似，区别在于MSVD低辐射镀膜上增加了两层抗反射MSVD镀膜，抗反射堆栈的组成如下。
层4：低折射率 24
层5：高折射率 25
实施例5
实施例5与实施例1相似，区别在于MSVD低辐射镀膜上增加了四层抗反射MSVD镀膜，抗反射堆栈的组成如下。
层4：低折射率 24
层5：高折射率 25
层6：低折射率 26
层7：高折射率 27
实施例6
实施例6与实施例2相似，区别在于MSVD低辐射镀膜上增加了四层抗反射MSVD镀膜，抗反射堆栈的组成如下。
层4：低折射率 24
层5：高折射率 25
层6：低折射率 26
层7：高折射率 27
实施例7
实施例7与实施例1相似，区别在于MSVD低辐射镀膜上增加了三层抗反射MSVD镀膜，抗反射堆栈的组成如下。
层4：低折射率 24
层5：高折射率 25
层6：中折射率 26
实施例8
实施例8与实施例2相似，区别在于MSVD低辐射镀膜上增加了三层抗反射MSVD镀膜，抗反射堆栈的组成如下。
层4：低折射率 24
层5：高折射率 25
层6：中折射率 26
实施例9-16
构成实施例9-16的八个实施例是通过在实施例1-8的夹层玻璃上增加防指纹镀膜的附加步骤而产生。防指纹镀膜可以通过MSVD工艺或任何其他适合该镀膜的方法来应用。

Claims (16)

1.一种汽车夹层玻璃，其特征在于，包括：
弯曲的玻璃外层，具有两个相对设置的主要面，分别为第一表面和第二表面；
玻璃内层，具有两个相对设置的主要面，分别为第三表面和第四表面；其中，所述玻璃内层是化学强化玻璃层，厚度小于等于1.0毫米；
低辐射镀膜，设置在所述玻璃内层的所述第四表面上；以及
至少一个塑料粘合层，设置在所述第二表面和所述第三表面之间；
其中，所述玻璃内层在与所述玻璃外层连接在一起时采用了与所述玻璃外层相同的形状。
2.根据权利要求1所述的汽车夹层玻璃，其特征在于，所述低辐射镀膜由三层MSVD沉积的堆栈组成，包括SiNx/ITO/SiNx。
3.根据权利要求1所述的汽车夹层玻璃，其特征在于，所述低辐射镀膜由三层MSVD沉积的堆栈组成，包括SiOxNy/ITO/SiOxNy。
4.根据权利要求1所述的汽车夹层玻璃，其特征在于，进一步包括设置在所述低辐射镀膜上的抗反射镀膜。
5.根据权利要求4所述的汽车夹层玻璃，其特征在于，所述抗反射镀膜包括两层MSVD镀膜；其中，一层MSVD镀膜的折射率低于另一层MSVD镀膜的折射率。
6.根据权利要求4所述的汽车夹层玻璃，其特征在于，所述抗反射镀膜包括三层MSVD镀膜；其中，一层MSVD镀膜的折射率低于另一层MSVD镀膜的折射率且高于再另一层MSVD镀膜的折射率。
7.根据权利要求4所述的汽车夹层玻璃，其特征在于，所述抗反射镀膜包括四层MSVD镀膜；其中两层MSVD镀膜的折射率低于另外两层MSVD镀膜的折射率。
8.根据权利要求1所述的汽车夹层玻璃，其特征在于，进一步包括设置于所述汽车夹层玻璃的内部表面的防指纹镀膜。
9.根据权利要求4所述的汽车夹层玻璃，其特征在于，进一步包括设置于所述抗反射镀膜上的防指纹镀膜。
10.根据权利要求1所述的汽车夹层玻璃，其中，进一步包括设置在所述玻璃外层的所述第二表面上的红外线反射镀膜。
11.根据权利要求1所述的汽车夹层玻璃，其中，进一步包括层叠设置的红外线反射镀膜。
12.一种生产汽车夹层玻璃的方法，所述汽车夹层玻璃包括至少两个玻璃层；其特征在于，所述方法包括：
提供弯曲的玻璃外层，所述玻璃外层具有两个相对设置的主要面，分别为第一表面和第二表面；
提供玻璃内层，所述玻璃内层具有两个相对设置的主要面，分别为第三表面和第四表面；其中，
i.所述玻璃内层的厚度小于等于1.0毫米；
ii.当作为车窗安装时，所述第四表面包括车辆乘客舱的内表面；
对所述玻璃内层进行切割、边缘处理、清洁，并根据需要对所述玻璃内层进行离子交换化学强化的准备；
对所述玻璃内层通过离子交换过程进行化学强化；
对所述玻璃内层的包括所述车辆乘客舱内表面的所述第四表面上设置低辐射镀膜；
在所述第二表面和所述第三表面之间提供至少一个塑料粘合层；
在层压过程中，对经过强化和镀膜的所述玻璃内层进行冷弯处理以采用与所述玻璃外层相同的形状。
13.根据权利要求12所述的方法，其特征在于，进一步包括对所述低辐射镀膜进行热活化。
14.根据权利要求12所述的方法，其特征在于，进一步包括在所述低辐射镀膜上设置抗反射镀膜。
15.根据权利要求12所述的方法，其特征在于，进一步包括在所述汽车夹层玻璃的内部表面设置防指纹镀膜。
16.根据权利要求12所述的方法，其特征在于，进一步包括增设层叠设置的红外线反射镀膜。
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