Single layer thermal barrier sputtered polyester energy saving film
Patent Information
- Application Number
- CN202521349859.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-06-30
- Publication Date
- 2026-08-21
- Estimated Expiration
- 2035-06-30
AI Technical Summary
现有主流产品多采用多层银合金膜结构，但存在以下技术瓶颈：多层银合金层易因界面应力导致膜层脱落，且银元素在湿热环境中易被硫化腐蚀，造成红外反射率衰减；多层膜需在透光率、隔热率、颜色一致性之间反复调试，生产工艺复杂，良率低；多层溅射工序增加设备损耗和生产周期，难以满足大规模应用需求
[0005]本实用新型的有益效果： 可见光透光率 65%（360-740nm），满足室内 / 车内采光需求，蓝紫色外观（色坐标 x=0.20-0.25，y=0.25-0.30）通过膜层干涉色实现，兼具美观性；950nm 波长隔热率 40%，通过单层银合金与高低折射层的反射协同，等效于传统 3 层银膜的隔热效果，减少膜层厚度 30% 以上。；阻隔层（SiO2/Al2O3）的致密结构（孔隙率≤5%）有效阻挡水汽、硫化物渗透，经 800 小时耐候测试（65℃、80% 湿度、300-400nm 紫外线 60W/㎡），隔热率衰减≤8%，透光率变化≤3%；折射率梯度匹配（相邻层差值≤0.8）降低界面应力，膜层附着力达 5B 级（划格法测试），耐摩擦次数≥5000 次（250g 负载）；单层银合金设计减少 2-3 层溅射工序，生产效率提升 20%，靶材利用率提高 15%；标准化的磁控溅射参数（如氩气流量、靶基距）便于工业化量产，良率≥95%。
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Figure CN224662987U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of energy-saving thin film materials technology, specifically a single-layer heat-insulating sputtered polyester energy-saving film with optimized optical performance. Background Technology
[0002] In the field of energy conservation in architectural and automotive glass, functional window films achieve the energy-saving effect of "allowing light without absorbing heat" by selectively reflecting and absorbing solar radiation through the film layer. Current mainstream products mostly adopt a multi-layer silver alloy film structure, but this presents the following technical bottlenecks: the multi-layer silver alloy layer is prone to film detachment due to interfacial stress, and silver is easily corroded by sulfidation in humid and hot environments, causing a decrease in infrared reflectivity; multi-layer films require repeated adjustments between light transmittance, heat insulation rate, and color consistency, resulting in complex production processes and low yields; the multi-layer sputtering process increases equipment wear and production cycle, making it difficult to meet the needs of large-scale applications. To address the aforementioned issues, this invention employs a precise refractive index matching design between a single-layer silver alloy layer and high / low refractive index layers, achieving excellent heat insulation and light transmission performance while reducing the number of film layers, thus overcoming existing technological limitations. Summary of the Invention
[0003] The purpose of this invention is to provide a single-layer heat-insulating sputtered polyester energy-saving film with stable structure and excellent optical performance. Through the refractive index gradient matching of the five film layers, the synergistic optimization of high light transmittance, high heat insulation and long life is achieved.
[0004] To achieve the above objectives, this utility model provides the following technical solution: A single-layer heat-insulating sputtered polyester energy-saving film is characterized by comprising a base layer, wherein a niobium oxide layer, a zinc aluminum oxide layer, a silver alloy layer, a barrier layer and a protective layer are sequentially disposed on the base layer to form a coating structure with a thickness of 5 film layers; wherein the silver alloy layer is a single layer and is formed into a thin film by magnetron sputtering coating process to achieve reflection of infrared spectrum. The present invention further comprises that the thickness of the niobium oxide layer is 5-10 nm, the thickness of the zinc-aluminum oxide layer is 10-20 nm, the thickness of the silver alloy layer is 15-25 nm, the thickness of the barrier layer is 10-20 nm, and the thickness of the protective layer is 5-10 nm. The present invention further comprises a silver alloy layer composed of silver, copper, and nickel, wherein the silver content is 80-90%, the copper content is 5-10%, and the nickel content is 5-10%. In a further embodiment of this invention, the barrier layer is made of silicon dioxide or aluminum oxide. The present invention further provides that the energy-saving film has a light transmittance of 65% in the visible light range of 360-740nm and a heat insulation rate of 40% at a wavelength of 950nm. The present invention is further configured such that the niobium oxide layer and the zinc aluminum oxide layer form a high refractive index layer, and the barrier layer and the protective layer form a low refractive index layer, and a refractive index matching relationship is formed between each film layer. The present invention further comprises a high refractive layer consisting of a niobium oxide layer with a refractive index of 2.0-2.3 and a zinc aluminum oxide layer with a refractive index of 1.9-2.2, both of which have a refractive index of 1.0 relative to air.
[0005] The beneficial effects of this utility model are as follows: Visible light transmittance is 65% (360-740nm), meeting the lighting requirements of indoor / vehicle interiors; the blue-purple appearance (color coordinates x=0.20-0.25, y=0.25-0.30) is achieved through film interference colors, which also enhances aesthetics; the 950nm wavelength heat insulation rate is 40%, achieved through the synergistic reflection of a single-layer silver alloy and high and low refractive layers, equivalent to the heat insulation effect of a traditional 3-layer silver film, reducing the film thickness by more than 30%. The dense structure (porosity ≤5%) of the barrier layer (SiO2 / Al2O3) effectively blocks the penetration of water vapor and sulfides. After 800 hours of weathering test (65℃, 80% humidity, 300-400nm ultraviolet 60W / ㎡), the heat insulation rate decreases by ≤8% and the light transmittance changes by ≤3%. The refractive index gradient matching (difference between adjacent layers ≤0.8) reduces interfacial stress, and the film adhesion reaches 5B level (cross-cut test). The abrasion resistance is ≥5000 cycles (250g load). The single-layer silver alloy design reduces 2-3 sputtering processes, improves production efficiency by 20%, and increases target utilization by 15%. The standardized magnetron sputtering parameters (such as argon flow rate and target-substrate distance) facilitate industrial mass production, with a yield of ≥95%. Attached Figure Description
[0006] Figure 1 This is a schematic diagram of the structure of this utility model. Detailed Implementation
[0007] The following will describe in detail the implementation of this application with reference to the accompanying drawings and embodiments, so that the implementation process of how this application uses technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly.
[0008] This utility model provides a single-layer heat-insulating sputtered polyester energy-saving film, including a base layer, on which a niobium oxide layer, a zinc aluminum oxide layer, a silver alloy layer, a barrier layer and a protective layer are sequentially disposed, forming a coating structure with a thickness of 5 film layers; the silver alloy layer is a single layer, which is formed into a thin film by magnetron sputtering coating process to achieve reflection of infrared spectrum. The thickness of the niobium oxide layer is 5-10 nm, the thickness of the zinc-aluminum oxide layer is 10-20 nm, the thickness of the silver alloy layer is 15-25 nm, the thickness of the barrier layer is 10-20 nm, and the thickness of the protective layer is 5-10 nm. The silver alloy layer is composed of silver, copper, and nickel, wherein the silver content is 80-90%, the copper content is 5-10%, and the nickel content is 5-10%. The barrier layer is made of silicon dioxide or aluminum oxide. Specifically: the niobium oxide layer and the zinc aluminum oxide layer form a high refractive index layer, and the barrier layer and the protective layer form a low refractive index layer, with a refractive index matching relationship between each film layer. High refractive index layer: composed of niobium oxide (refractive index 2.0-2.3) and zinc aluminum oxide (refractive index 1.9-2.2). The refractive index of zinc aluminum oxide is precisely adjusted by doping with aluminum (1-5%), forming a refractive index difference of 0.1-0.4 with niobium oxide, thus constructing a gradient high refractive index transition layer; Infrared reflective core layer: a single-layer silver alloy layer (Ag 80-90%, Cu 5-10%, Ni 5-10%), which utilizes the high reflectivity of metals to 950nm infrared light (reflectivity ≥40%) to achieve heat insulation function; Low-refractive protective layer: The barrier layer (SiO2 or Al2O3, refractive index 1.45-1.7) and the protective layer (of the same material) form a low-refractive range, and form a refractive index difference of 0.4-0.8 with the high-refractive layer, which satisfies the optical interference anti-reflection condition. At the same time, the dense structure protects the silver alloy layer from external corrosion.
[0009] The energy-saving film has a light transmittance of 65% in the visible light range of 360-740nm and a heat insulation rate of 40% at a wavelength of 950nm. This utility model also provides a process for preparing a single-layer heat-insulating sputtered polyester energy-saving film, characterized by the following steps: Substrate pretreatment: The polyester substrate is ultrasonically cleaned with deionized water for 10-20 minutes, wiped with alcohol, and then dried at 70-90℃ for 15-30 minutes. Magnetron sputtering coating: In a vacuum environment, a niobium oxide layer, a zinc aluminum oxide layer, a silver alloy layer, a barrier layer, and a protective layer are sputtered sequentially onto the substrate; Post-processing: Cooling and testing the coated energy-saving film. During the magnetron sputtering coating process, the purity of the niobium oxide target is ≥99.9%, the aluminum content in the zinc-aluminum oxide target is 1-5%, and the density of the silver alloy target is 9.5-10.5 g / cm³. High-purity argon is used as the sputtering gas in the magnetron sputtering process. The argon flow rate is controlled at 50-100 sccm. The distance between the target and the polyester substrate is maintained at 80-150 mm during the sputtering of each film layer. The target is pre-sputtered for 5-10 minutes before sputtering each film layer to remove the surface oxide layer.
[0010] The beneficial effects of this utility model are as follows: Visible light transmittance is 65% (360-740nm), meeting the lighting requirements of indoor / vehicle interiors; the blue-purple appearance (color coordinates x=0.20-0.25, y=0.25-0.30) is achieved through film interference colors, which also enhances aesthetics; the 950nm wavelength heat insulation rate is 40%, achieved through the synergistic reflection of a single-layer silver alloy and high and low refractive layers, equivalent to the heat insulation effect of a traditional 3-layer silver film, reducing the film thickness by more than 30%. The dense structure (porosity ≤5%) of the barrier layer (SiO2 / Al2O3) effectively blocks the penetration of water vapor and sulfides. After 800 hours of weathering test (65℃, 80% humidity, 300-400nm ultraviolet 60W / ㎡), the heat insulation rate decreases by ≤8% and the light transmittance changes by ≤3%. The refractive index gradient matching (difference between adjacent layers ≤0.8) reduces interfacial stress, and the film adhesion reaches 5B level (cross-cut test). The abrasion resistance is ≥5000 cycles (250g load). The single-layer silver alloy design reduces 2-3 sputtering processes, improves production efficiency by 20%, and increases target utilization by 15%. The standardized magnetron sputtering parameters (such as argon flow rate and target-substrate distance) facilitate industrial mass production, with a yield of ≥95%. Example
[0011] Grassroots handling: Select a 100μm thick PET substrate, ultrasonically clean it with deionized water for 15 minutes, wipe it with anhydrous ethanol, and then dry it at 80℃ for 20 minutes. Magnetron sputtering parameters: Niobium oxide layer: target purity 99.95%, power 120W, argon flow rate 80sccm, spacing 100mm, sputtering for 8 minutes (thickness 8nm, refractive index 2.2). Zinc oxide aluminum layer: Al content 3%, power 150W, argon flow rate 90sccm, spacing 120mm, sputtering for 12 minutes (thickness 15nm, refractive index 2.0). Silver alloy layer: Ag 85%, Cu 7.5%, Ni 7.5%, power 200W, argon flow rate 100sccm, spacing 150mm, sputtering for 18 minutes (thickness 20nm). Barrier layer (SiO2): power 100W, argon flow rate 60sccm, spacing 100mm, sputtering for 15 minutes (thickness 15nm, refractive index 1.48). Protective layer (SiO2): power 80W, argon flow rate 50sccm, spacing 100mm, sputtering for 5 minutes (thickness 5nm). Performance testing: Transmittance: 65.2% (360-740nm), color coordinates (0.23, 0.28); Thermal insulation rate: 41.2% (950nm), thermal insulation rate after 1000 hours of weathering test: 38.5% (attenuation of 6.5%), light transmittance: 63.8% (change of -2.1%). Example 2: Grassroots handling: Select a 50μm thick PET substrate, ultrasonically clean it with deionized water for 10 minutes, wipe it with isopropanol, and then dry it at 75℃ for 30 minutes. Magnetron sputtering parameters: Niobium oxide layer: 100W power, sputtering for 5 minutes (thickness 5nm, refractive index 2.3); Zinc oxide aluminum layer: Al content 5%, power 180W, sputtering for 10 minutes (thickness 10nm, refractive index 1.9). Silver alloy layer: Ag 80%, Cu 10%, Ni 10%, power 220W, sputtering for 15 minutes (thickness 15nm); Barrier layer (Al2O3): Power 150W, sputtering for 20 minutes (thickness 20nm, refractive index 1.65). Protective layer (Al2O3): power 120W, sputtering for 8 minutes (thickness 8nm). Performance testing: Light transmittance: 64.8%, color coordinates (0.22, 0.27); Thermal insulation rate: 40.5%, no film peeling after abrasion resistance test (3000 times), adhesion grade 5B.
[0012] Example 3 Substrate preparation: Select a 75μm thick PET substrate, ultrasonically clean with deionized water for 12 minutes, wipe with alcohol and dry at 85℃ for 25 minutes. Magnetron sputtering parameters: Niobium oxide layer: target purity 99.92%, power 110W, argon flow rate 75sccm, spacing 110mm, sputtering for 7 minutes (thickness 7nm, refractive index 2.25). Zinc oxide aluminum layer: Al content 2%, power 140W, argon flow rate 85sccm, spacing 130mm, sputtering for 11 minutes (thickness 13nm, refractive index 2.05). Silver alloy layer: Ag 88%, Cu 6%, Ni 6%, power 190W, argon flow rate 95sccm, spacing 140mm, sputtering for 17 minutes (thickness 18nm). Barrier layer (SiO2): power 90W, argon flow rate 55sccm, spacing 90mm, sputtering for 14 minutes (thickness 14nm, refractive index 1.5). Protective layer (SiO2): power 70W, argon flow rate 45sccm, spacing 85mm, sputtering for 6 minutes (thickness 6nm). Performance testing: Transmittance: 65.5% (360 - 740nm), color coordinates (0.24, 0.29); Thermal insulation rate: 40.8% (950nm), thermal insulation rate after 1200 hours of weathering test: 38.2% (attenuation of 6.4%), light transmittance: 64.2% (change of -1.9%). Example 4 Substrate preparation: Use a 60μm thick PET substrate, ultrasonically clean with deionized water for 18 minutes, wipe with isopropyl alcohol and dry at 90℃ for 18 minutes. Magnetron sputtering parameters: Niobium oxide layer (NbOx): With a target power of 100W, the winding speed is coordinated with the overall production line, and the coating time is uniform, the deposition thickness is ~5nm, and the refractive index is 2.3.
[0013] Zinc oxide aluminum layer (AZO): Al content 5% target material, power 180W. In continuous roll-to-roll production, at the same speed and coating time as the production line, deposition thickness ~10nm, refractive index 1.9.
[0014] Silver alloy layer (Ag-Cu-Ni): An alloy target with a composition of 80% Ag, 10% Cu, and 10% Ni was used, with a power of 220W. A deposition thickness of ~15nm was achieved using a uniform winding speed and deposition time.
[0015] Barrier layer (Al2O3): Al2O3 target material, power 150W. Within the roll-to-roll production process, with uniform coating time and speed, deposition thickness ~20nm, refractive index 1.65.
[0016] Protective layer (Al2O3): Al2O3 target material, 120W power. Following the uniform speed and coating time of the roll-to-roll production line, the deposition thickness is ~8nm. Performance testing: Light transmittance: 64.6%, color coordinates (0.21, 0.26); Thermal insulation rate: 40.3%, no damage to the film layer after abrasion resistance test (4000 times), adhesion grade 5B. Comparative Example 1 (Traditional Three-Layer Silver Alloy Film) Membrane structure: The polyester base layer consists of a silicon oxide layer (10nm), a silver alloy layer (8nm), a titanium dioxide layer (12nm), a silver alloy layer (8nm), a silicon oxide layer (10nm), a silver alloy layer (8nm), and a protective layer (10nm). Preparation process: Ordinary magnetron sputtering equipment was used, without pre-sputtering treatment of the target material, and the argon flow rate was unstable (fluctuating between 30 and 120 sccm). Performance testing: Light transmittance: 58% (360 - 740nm); Heat insulation rate: 38% (950nm). After 500 hours of weathering test, the heat insulation rate dropped to 32% (attenuation of 15.8%), the light transmittance dropped to 53% (change of -8.6%), and some film layers peeled off. Comparative Example 2 (film without refractive index matching design) The film structure consists of a niobium oxide layer (15nm), a zinc oxide layer (25nm), a silver alloy layer (15-25nm), a barrier layer (25nm), and a protective layer (15nm) on a polyester substrate. No refractive index optimization design was performed on any of the film layers. Preparation process: Same as in Example 1, but the refractive index of each film layer was not controlled. Performance testing: Light transmittance: 52% (360 - 740nm); Thermal insulation rate: 35% (950nm), the film surface color is uneven, the adhesion is only 3B grade, and the number of abrasion cycles is only 1500 (250g load).
[0017] If certain terms are used in the specification and claims to refer to specific components, those skilled in the art will understand that hardware manufacturers may use different names to refer to the same component. This specification and claims do not distinguish components based on differences in name, but rather on differences in function. The term "comprising" as used throughout the specification and claims is an open-ended term and should be interpreted as "comprising but not limited to." "Approximately" means that within an acceptable margin of error, those skilled in the art can solve the technical problem and substantially achieve the technical effect within a certain margin of error.
[0018] It should be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a product or system comprising a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a product or system. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the product or system that includes that element.
[0019] The foregoing description illustrates and describes several preferred embodiments of the present invention. However, as previously stated, it should be understood that the present invention is not limited to the forms disclosed herein and should not be construed as excluding other embodiments. It can be used in various other combinations, modifications, and environments, and can be altered within the scope of the inventive concept by means of the foregoing teachings or techniques or knowledge in related fields. Any modifications and variations made by those skilled in the art that do not depart from the spirit and scope of the present invention should be within the protection scope of the appended claims.
Claims
1. A single-layer heat-insulating sputtered polyester energy-saving film, characterized in that: The substrate includes a niobium oxide layer, a zinc aluminum oxide layer, a silver alloy layer, a barrier layer, and a protective layer, which are sequentially disposed on the substrate to form a coating structure with a thickness of 5 film layers; the silver alloy layer is a single layer, which is formed into a thin film by magnetron sputtering coating process to achieve reflection of infrared spectrum.
2. The single-layer heat-insulating sputtered polyester energy-saving film according to claim 1, characterized in that: The thickness of the niobium oxide layer is 5-10 nm, the thickness of the zinc-aluminum oxide layer is 10-20 nm, the thickness of the silver alloy layer is 15-25 nm, the thickness of the barrier layer is 10-20 nm, and the thickness of the protective layer is 5-10 nm.
3. The single-layer heat-insulating sputtered polyester energy-saving film according to claim 1, characterized in that: The barrier layer is made of silicon dioxide or aluminum oxide.
4. The single-layer heat-insulating sputtered polyester energy-saving film according to claim 1, characterized in that: The energy-saving film has a light transmittance of 65% in the visible light range of 360-740nm and a heat insulation rate of 40% at a wavelength of 950nm.
5. The single-layer heat-insulating sputtered polyester energy-saving film according to claim 1, characterized in that: The niobium oxide layer and the zinc-aluminum oxide layer form a high-refractive-index layer, and the barrier layer and the protective layer form a low-refractive-index layer, with a refractive index matching relationship between each film layer.