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TW202128426A - 複數層構造體 - Google Patents

複數層構造體 Download PDF

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Publication number
TW202128426A
TW202128426A TW109132778A TW109132778A TW202128426A TW 202128426 A TW202128426 A TW 202128426A TW 109132778 A TW109132778 A TW 109132778A TW 109132778 A TW109132778 A TW 109132778A TW 202128426 A TW202128426 A TW 202128426A
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TW
Taiwan
Prior art keywords
layer
resin
glass
adhesive
plural
Prior art date
Application number
TW109132778A
Other languages
English (en)
Other versions
TWI877227B (zh
Inventor
村重毅
稻垣淳一
佐藤啓介
岸敦史
Original Assignee
日商日東電工股份有限公司
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Publication of TW202128426A publication Critical patent/TW202128426A/zh
Application granted granted Critical
Publication of TWI877227B publication Critical patent/TWI877227B/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B32B17/10761—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 vinyl acetal
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    • B32B17/10082—Properties of the bulk of a glass sheet
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Abstract

本發明提供一種複數層構造體，其具有厚度為10μm以上200μm以下的玻璃層、以及樹脂層，將一個玻璃層與一個樹脂層的層疊構造作為單位層疊構造，在該複數層構造體的厚度方向中，該單位層疊構造的數量為5層以上20000層以下。

Description

複數層構造體
本發明係關於具有玻璃層和樹脂層的複數層構造體。
將玻璃和樹脂薄膜重疊複數層而成的複數層構造體作為同時具有玻璃所具有的剛性和樹脂所具有的韌性的複合材料為人所知。該複數層構造體具有如下效果，即，對於高強度的衝擊，藉由反復對玻璃的破壞以及樹脂的衝擊吸收，使外部衝擊急劇減小。由於這樣的特徵，該複數層構造體被廣泛用於作為防彈玻璃、安全防禦用的玻璃防止相對於來自外部的衝擊而龜裂破損的用途。
<先前技術文獻>
<專利文獻>
專利文獻1：日本特開2003-192402號公報
以往的複數層構造體使用複數張具有數mm厚度的平板玻璃，複數層的數量越多耐衝擊性越高，但是由於玻璃比重較大，因此重量的問題成為課題。為了擴展玻璃的活用場景，使玻璃彎曲的曲面玻璃雖然從設計性的觀點出發被用於陳列櫃、建築部件等，但是為了將複數層構造體應用於曲面玻璃，需要使複數層構造體熱變形為曲面形狀，在數百度的玻璃的軟化點下樹脂層熱分解，因此不現實。雖然亦存在事 先形成玻璃曲面，然後與樹脂層疊的方式，但是難以獲得較高生產率。
另外，若能獲得圓筒的複數層構造體，則能夠用作高強度的配管坯料，至今為止雖然能夠向化學設備等提供在金屬表面實施了玻璃處理的不破裂的透明的可視覺辨認的配管，但使玻璃管和樹脂管複數層疊卻極其困難。
本發明鑒於上述的點而成，其目的在於，提供一種具有玻璃層與樹脂層的多層複合構造，且能夠成形為任意形狀的複數層構造體。
本複數層構造體具有厚度為10μm以上200μm以下的玻璃層、以及樹脂層，將一個玻璃層與一個樹脂層的層疊構造作為單位層疊構造，在該複數層構造體的厚度方向中，該單位層疊構造的數量為5層以上20000層以下。
根據公開的技術，能夠提供一種具有玻璃層與樹脂層的多層複合構造，且能夠成形為任意形狀的複數層構造體。
10、10A、10B:複數層構造體
10C、10D:板
11:玻璃層
12:樹脂層
13:單位層疊構造
121:樹脂薄膜
122:粘接層
122A:粘接劑
圖1是舉例示出本實施方式的複數層構造體的立體圖。
圖2是舉例示出本實施方式的變形例1的複數層構造體的立體圖。
圖3是舉例示出本實施方式的變形例2的複數層構造體的立體圖。
圖4A是舉例示出本實施方式的複數層構造體的橫剖面的形狀的剖視圖(其一)。
圖4B是舉例示出本實施方式的複數層構造體的橫剖面的形狀的剖視圖(其二)。
圖4C是舉例示出本實施方式的複數層構造體的橫剖面的形狀的剖視圖(其三)。
圖4D是舉例示出本實施方式的複數層構造體的橫剖面的形狀的剖視圖(其四)。
圖5A是舉例示出本實施方式的複數層構造體的樹脂層的構造的剖視圖(其一)。
圖5B是舉例示出本實施方式的複數層構造體的樹脂層的構造的剖視圖(其二)。
圖6是舉例示出樹脂層僅由粘接層構成的情況下的複數層構造體的製造方法的圖。
圖7是舉例說明樹脂層由樹脂薄膜和粘接層構成的情況下的複數層構造體的製造方法的圖(其一)。
圖8是舉例說明樹脂層由樹脂薄膜和粘接層構成的情況下的複數層構造體的製造方法的圖(其二)。
圖9A是舉例說明樹脂層由樹脂薄膜和粘接層構成的情況下的複數層構造體的製造方法的圖(其三)。
圖9B是舉例說明樹脂層由樹脂薄膜和粘接層構成的情況下的複數層構造體的製造方法的圖(其四)。
圖10是表示截斷本實施方式的複數層構造體的柱狀構造的例子的立體圖(其一)。
圖11是表示截斷本實施方式的複數層構造體的柱狀構造的例子的立體圖(其二)。
以下，參照附圖對發明的實施方式進行說明。各附圖中，對於相同的構成部分付與相同的符號，並且有時省略重複的說明。
〔複數層構造體〕
圖1是舉例示出本實施方式的複數層構造體的立體圖。如圖1所示，複數層構造體10是玻璃層11與樹脂層12複數層交替配置的構造。
更具體而言，複數層構造體10為如下構造，即，將一個玻璃層11與一個樹脂層12的層疊構造作為單位層疊構造13，在複數層構造體10的厚度方向(層疊方向)中，單位層疊構造13以玻璃層11與樹脂層12交替配置的方式複數個層疊固定。需要說明的是，單位層疊構造13亦可以彼此藉由粘接層或粘合層進行層疊。
在單位層疊構造13中，例如，玻璃層11與樹脂層12是相同的厚度。但是，在單位層疊構造13中，玻璃層11與樹脂層12亦可以厚度不同。另外，亦可以是對玻璃層 11與樹脂層12的厚度為任意的厚度從而層疊的厚度不同的複數種的單位層疊構造進行組合。
單位層疊構造13的層數為5層~20000層，優選為10層~1000層，更優選為20層~100層。若在該範圍內，則能夠獲得兼顧輕便和耐衝擊性的複數層構造體10。需要說明的是，在各圖中，為了便於製作附圖，存在單位層疊構造13的層疊數比5層少的情況，但實際上，單位層疊構造13的層數為5層以上20000層以下。
圖2是舉例示出本實施方式的變形例1的複數層構造體的立體圖。複數層構造體的構造可以如圖1所示複數層構造體10那樣，玻璃層11與樹脂層12的主面為平面，亦可以如圖2所示複數層構造體10A那樣，玻璃層11與樹脂層12的主面為曲面。或者，對於本實施方式的複數層構造體的構造，亦可以是玻璃層11與樹脂層12的主面為平面的部分與曲面的部分組合。
圖3是舉例示出本實施方式的變形例2中的複數層構造體的立體圖。如圖3所示複數層構造體10B那樣，若將單位層疊構造13層疊為輥狀，則能夠代表性地構成圓筒形狀。在圖3中，複數層構造體10B的中心附近的S表示空間。
如圖4A所示，複數層構造體10B的柱狀構造的橫剖面例如為圓。但是，複數層構造體10B的柱狀構造的橫剖 面不限定為圓，可以為如圖4B所示的橢圓，亦可以為如圖4C、圖4D所示的直線與曲線的組合。圖4C的剖面的例子為角部帶有圓角的長方形，圖4D的剖面的例子為角部帶有圓角的六邊形。
〔玻璃層〕
玻璃層11不特別限定，能夠根據目的採用合適的玻璃。根據基於組成的分類，玻璃層11例如能夠舉出堿石灰玻璃、硼酸玻璃、鋁矽酸鹽玻璃、石英玻璃等。另外，根據基於堿成分的分類，能夠舉出無堿玻璃、低堿玻璃。優選上述玻璃的鹼金屬成分(例如，Na2O、K2O、Li2O)的含有量為15重量%以下，更優選為10重量%以下。
玻璃層11的厚度t1例如為10μm以上200μm以下。這裡，10μm~200μm的厚度的玻璃層是指，玻璃層的平均厚度為10μm~200μm的玻璃層。
考慮玻璃所具有的表面硬度、氣密性以及耐腐蝕性，優選玻璃層11的厚度t1為10μ以上。另外，由於期望在獲得曲面構造基礎上單一的玻璃層11具有薄膜那樣的撓性，因此優選玻璃層11的厚度t1為200μm以下。特別優選為50μm~100μm。
優選玻璃層11的在波長550nm中的透光率為85%以上。優選玻璃層11的在波長550nm中的折射率為1．4~1．65。優選玻璃層11的密度為2．3g/ cm3~3．0g/cm3，更優選為2．3g/cm3~2．7g/cm3。
玻璃層11的成形方法不特別限定，能夠根據目的採用合適的方法。代表而言，玻璃層11可以將包含矽和/或氧化鋁等的主原料、芒硝和/或氧化銻等的消泡剖、以及碳等的還原劑的混合物以1400℃~1600℃左右的溫度熔融，使其成形為薄板狀後，進行冷卻來製作。作為玻璃層11的成形方法，例如可以舉出狹縫下拉法、熔融法、浮法等。藉由這些方法成形為板狀的玻璃層為了薄板化、提高平滑性，亦可以根據需要，藉由氫氟酸等的溶劑進行化學研磨。
〔樹脂層〕
本申請中，樹脂層是指包含樹脂成分的層。樹脂層亦可以包括用於形成樹脂層的無機粒子等的添加劑。具體而言，僅由粘接層、粘合層或者中間膜構成的層符合樹脂層。圖5A是樹脂層12僅由粘接層、粘合層或者中間膜構成的例子。
另外，將具有撓性的樹脂薄膜與玻璃層藉由粘接層或者粘合層進行層疊的情況下，具有樹脂薄膜與粘接層或粘合層的層符合樹脂層。亦就是說，在單位層疊構造中，樹脂層可以是包括具有撓性的樹脂薄膜、以及設於玻璃層與樹脂薄膜之間的粘接層或粘合層的構成。圖5B是樹脂層12由樹脂薄膜121和粘接層122構成的例子。樹脂層12亦可以替代粘接層122而具有粘合層。
樹脂層12的厚度t2例如為0．1μm~2mm。這裡，0．1μm~2mm的厚度的樹脂層是指，樹脂層的平均厚度為0．1μm~2mm的樹脂層。
〔樹脂薄膜〕
作為撓性的樹脂基材，例如，可以舉出聚醚碸類樹脂；聚碳酸酯類樹脂；丙烯酸類樹脂；聚對苯二甲酸乙二醇酯類樹脂、聚萘二甲酸乙二醇酯類樹脂等的聚酯類樹脂；聚烯烴類樹脂；降冰片烯類樹脂等的環烯烴類樹脂；聚醯亞胺類樹脂；聚醯胺類樹脂；聚醯亞胺醯胺類樹脂；聚芳酯類樹脂；聚碸類樹脂；聚醚醯亞胺類樹脂等。其中，優選使用聚對苯二甲酸乙二醇酯、聚碳酸酯、聚烯烴。樹脂基材的顏色不特別限定，但從透明性的觀點來說不透明的樹脂基材不優選。優選樹脂薄膜的厚度為25μm~1mm左右。特別優選為50μm~500μm。
〔粘接劑、粘合劑、中間膜〕
作為粘接劑或粘合劑，可以使用任意的適合的粘接劑或粘合劑。具體而言，能夠舉出丙烯酸類粘合劑、矽樹脂類粘合劑、橡膠類粘合劑、紫外線固化性丙烯酸類粘接劑、紫外線固化性環氧樹脂類粘接劑、熱固化性環氧樹脂類粘接劑、熱固化性三氯氰胺類粘接劑、熱固化性苯酚類粘接劑。
另外，作為中間膜，可以利用乙烯-醋酸乙烯酯共聚物(EVA)的中間膜、聚乙烯醇縮丁醛(PVB)等的聚乙烯縮 醛類樹脂的中間膜、聚氯乙烯(PVC)等的聚鹵乙烯樹脂的中間膜等。粘接層、粘合層以及中間膜的厚度在樹脂層的厚度的範圍內即可，不特別限定。
〔複數層構造體的製造方法〕
(樹脂層12僅由粘接層、粘合層、或中間膜構成的情況)
圖6是舉例示出樹脂層僅由粘接層構成的情況的複數層構造體的製造方法的圖。樹脂層12僅由粘接層構成的情況下，例如，藉由如圖6所示方法，可以製造複數層構造體10B。樹脂層12僅由粘合層或中間膜構成的情況下，藉由與圖6相同的方法，能夠製造複數層構造體10B。
具體而言，一邊自放出輥300沿箭頭方向放出纏卷於放出輥300的玻璃層11，一邊在玻璃層11的一個面層疊粘接劑122A，然後捲繞於具有期望的內徑卷取輥350。粘接劑122A為液狀的情況下，使用固化裝置400使粘接劑122A固化而作為樹脂層12。固化裝置400例如為紫外線照射裝置、加熱裝置。之後，藉由除去卷取輥350，可以獲得作為玻璃層11與樹脂層12的層疊構造的單位層疊構造13被層疊為期望的層數的複數層構造體10B。樹脂層12由粘接劑122A固化後的粘接層構成。
需要說明的是，作為樹脂層12使用EVA、PVB等的中間膜時，優選一邊給予熱量一邊用卷取輥350進行捲繞。
另外，樹脂層12僅由中間膜構成的情況下，亦可以藉由將玻璃層11與樹脂層12的單位層疊構造13的中間膜一側的面與別的單位層疊構造13的玻璃層11一側熱壓接來製作複數層構造體10B。就原理而言，使其層疊時，藉由將單位層疊構造13的溫度升高至玻璃層11與中間膜能夠粘接的溫度，從而能夠製作複數層構造體10B。
例如，作為提高溫度的方法，在製作任意的柱狀構造(筒狀)的複數層構造體10B時，能夠舉出與層疊同時或在層疊後藉由將加熱的輥按壓於最外層來進行壓接的方法。另外，在預先製作使玻璃層11與中間膜層疊的單位層疊構造13的薄片的情況下，藉由提高層壓的輥的溫度，能夠獲得單位層疊構造13的薄片。作為獲得單位層疊構造13的別的方法，亦可以在使玻璃層11與中間膜重疊的狀態下暫時捲繞後，將輥置於真空下，使用紅外線等提高溫度進行粘接。
(樹脂層12由樹脂薄膜與粘接層或粘合層構成的情況)
圖7是舉例示出樹脂層由樹脂薄膜與粘接層構成的情況的複數層構造體的製造方法的圖。樹脂層12由樹脂薄膜與粘接層構成的情況下，例如，藉由如圖7所示方法，能夠 製造複數層構造體10B。樹脂層12由樹脂薄膜與粘合層構成的情況下，亦能夠藉由與圖7相同的方法製造複數層構造體10B。
具體而言，一邊自放出輥300和放出輥310沿箭頭方向放出纏卷於放出輥300的玻璃層11、纏卷於放出輥310的樹脂薄膜121，一邊在樹脂薄膜121的兩個面層疊粘接劑122A，然後捲繞於具有期望的內徑的卷取輥350。之後，藉由除去卷取輥350，能夠獲得作為玻璃層11與樹脂層12的層疊構造的單位層疊構造13被層疊期望的層數的複數層構造體10B。樹脂層12由樹脂薄膜121、粘接劑122A固化後的粘接層122構成。
需要說明的是，如圖8所示，代替在樹脂薄膜121的兩個面層疊粘接劑122A的方法，亦可以使用在玻璃層11的一個面以及在樹脂薄膜121的一個面分別層疊粘接劑122A的方法。圖8中，纏卷於放出輥320A和320B的薄膜狀的粘接劑122A供給至玻璃層11的一個面和樹脂薄膜121的一個面。
另外，亦可以使用以下的方法。
首先，如圖9A所示，一邊自放出輥300和放出輥310沿箭頭方向放出纏卷於放出輥300的玻璃層11和纏卷於放出輥310的樹脂薄膜121，一邊使用塗布機500向樹脂薄膜121的一個面層疊粘接劑122A，然後穿 過夾持輥330而捲繞於卷取輥360。由此，製作使玻璃層11與樹脂薄膜121藉由粘接劑122A層疊的複合輥10X。
接下來，如圖9B所示，一邊沿箭頭方向放出複合輥10X，一邊使用塗布機500在樹脂薄膜121的一個面層疊粘接劑122A，然後捲繞於具有期望的內徑的卷取輥350。之後，通過除去卷取輥350，能夠獲得作為玻璃層11與樹脂層12的層疊構造的單位層疊構造13被層疊為期望的層數的複數層構造體10B。該情況下，單位層疊構造13彼此藉由粘接層被層疊。圖9B中，亦可以在樹脂薄膜121的兩個面層疊粘接劑122A。
需要說明的是，在圖6~圖9B所示的任意的方法中，對於需要固化的粘接劑，需要一邊捲繞一邊藉由熱量、光進行固化，或者在捲繞之後藉由熱量、光進行固化。另外，對於液狀的粘接劑，能夠舉出如圖9A和圖9B所示的、使用塗布機500在樹脂薄膜121上進行塗布使其層疊的方法，或者如圖7所示的、在捲繞部分製作積液從而在捲繞的同時形成粘接劑的層的方法。
在圖6~圖9B所示任意的方法中，複數層構造體10B的厚度能夠根據捲繞的次數進行控制。另外，複數層構造體10B的內徑能夠通過選擇卷取輥350的外徑來任意進行控制。
另外，組合兩種以上的複數層構造體時，例如，藉由上述方法捲繞一種複數層構造體之後，在其上捲繞複數層由其他的厚度、材質構成的薄膜，從而能夠製作在圓筒的內側與外側由不同的複數層構造體構成的層疊體。該情況下，當然亦可以加入藉由粘接劑僅捲繞不包含玻璃的樹脂薄膜等的構成。
複數層構造體10B一般為圓筒，但藉由改變卷取輥350的形狀，能夠製作如圖4A~圖4D所示的各種形狀的複數層構造體10B。
而且，藉由截斷複數層構造體10B的柱狀構造，如圖10所示板10C、圖11所示板10D那樣，能夠獲得半圓、任意的曲面形狀的板。藉由組合板10C和板10D，能夠製作出各種立體構造。另外，藉由截斷複數層構造體10B的柱狀構造，能夠製作如圖1所示複數層構造體10、如圖2所示複數層構造體10A。
〔用途〕
本實施方式的複數層構造體例如能夠用於工業用的配管、建築材料、陳列櫃、曲面窗等。
這樣，本實施方式的複數層構造體為具有厚度10μm以上200μm以下的玻璃層與樹脂層的複數層構造體，以一個玻璃層與一個樹脂層的層疊構造為單位層疊構造，在複數層構造體的厚度方向中，單位層疊構造的數量為5層以上 20000層以下。由此，本實施方式的複數層構造體在採用吸收高強度的衝擊的玻璃層與樹脂層的多層複合構造的同時輕量，並且不止平面，其能夠任意成形為曲面、圓筒的形狀。
以上，對優選實施方式等進行了詳細說明，但不限於上述實施方式等，能夠不超出申請專利範圍記載的範圍地對上述實施方式等添加各種變形和置換。
本國際申請要求基於2019年9月26日申請的日本國發明專利申請2019-175837號的優先權，在本國際申請中引用日本國發明專利申請2019-175837號的全部內容。
10:複數層構造體
11:玻璃層
12:樹脂層
13:單位層疊構造
t1:玻璃層的厚度
t2:樹脂層的厚度

Claims (6)

  1. 一種複數層構造體，其具有厚度為10μm以上200μm以下的玻璃層、以及樹脂層，
    將一個玻璃層與一個樹脂層的層疊構造作為單位層疊構造，
    在該複數層構造體的厚度方向上，該單位層疊構造的數量為5層以上20000層以下。
  2. 如請求項1所述的複數層構造體，其中，
    在該單位層疊構造中，該樹脂層具有：
    樹脂薄膜，其具有撓性；以及
    粘接層或粘合層，其設於該玻璃層與該樹脂薄膜之間。
  3. 如請求項1所述的複數層構造體，其中，
    在該單位層疊構造中，該樹脂層為中間膜。
  4. 如請求項3所述的複數層構造體，其中，
    該中間膜為聚乙烯縮醛類樹脂或聚鹵乙烯樹脂。
  5. 如請求項1至4中任一項所述的複數層構造體，其中，
    該單位層疊構造彼此藉由粘接層或粘合層層疊。
  6. 如請求項1至5中任一項所述的複數層構造體，其中，
    該複數層構造體為筒狀。
TW109132778A 2019-09-26 2020-09-22 複數層構造體 TWI877227B (zh)

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EP4035890A1 (en) 2022-08-03
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