METHOD FOR MANUFACTURING SILVER-PLATED REFLECTING FILM

Abstract

This disclosure provides a method for manufacturing a silver-plated reflecting film. The method includes following steps: (1) manufacturing a reflecting polyester film layer; (2) coating a silver-plated layer on one surface of the reflecting polyester film layer by a vacuum sliver plating method, wherein the vacuum sliver plating methods comprises a vacuum evaporation plating method or a vacuum sputtering silver plating method; and (3) applying a protection layer film on the silver-plated layer and obtaining the silver-plated reflecting film.

Claims

1. A method for manufacturing a silver-plated reflecting film, wherein the manufacturing method comprises: manufacturing a reflecting polyester film layer; coating a silver-plated layer on one surface of the reflecting polyester film layer by a vacuum sliver plating method, wherein the vacuum sliver plating methods comprises a vacuum evaporation plating method or a vacuum sputtering silver plating method; and applying a protection layer film on the silver-plated layer and obtaining the silver-plated reflecting film.

2. The method for manufacturing the silver-plated reflecting film of claim 1, wherein the silver-plated layer is prepared by the vacuum sputtering silver plating method, which comprises: putting 99.99% silver in a target of a sputtering chamber, with Ar as a sputtering gas, a vacuum level of 10-1.010.sup.1 Pa, a working temperature of 850 C. to 1000 C., and a film forming speed of 0.01 mm/min to 5 mm/min; and forming a silver-plated layer on the reflecting polyester film layer.

3. The method for manufacturing the silver-plated reflecting film of claim 1, wherein after the forming the silver-plated layer on the reflecting polyester film layer, the method further comprising a step of performing an annealing treatment under nitrogen at the room temperature.

4. The method for manufacturing the silver-plated reflecting film of claim 1, wherein the silver-plated layer is prepared by the vacuum evaporation plating method, which comprises: putting 99.99% silver in a crucible of a evaporation chamber, with a vacuum level of 10-1.010.sup.1 Pa, a working temperature of 2000 C. to 2500 C., and a film forming speed of 0.01 mm/min to 5 mm/min; and forming a silver-plated layer on the reflecting polyester film layer.

5. The method for manufacturing the silver-plated reflecting film of claim 1, wherein the protection layer film is applied on the silver-plated layer by a dry-type film covering method.

6. The method for manufacturing the silver-plated reflecting film of claim 3, wherein the dry-type film covering method comprises following steps: the protection layer film passing through a heated channel of 90 C.; and pressing the protection layer film onto the silver-plated layer.

7. The method for manufacturing the silver-plated reflecting film of claim 1, further comprising rolling the silver-plated reflecting film up after the applying the protection layer film on the silver-plated layer.

8. The method for manufacturing the silver-plated reflecting film of claim 1, wherein the protection layer film is manufactured by a tape casting method, in which a polymer is melt-extruded by a single-screw extruder to form a film on a cold roller, thereby obtaining the protection layer film by drawing and rolling up.

9. The method for manufacturing the silver-plated reflecting film of claim 8, wherein the reflecting polyester film layer is prepared by a physical foaming process that comprises: melting and plastifying a master batch containing additives and supercritical carbon dioxide; shearing and mixing the same into a uniform solution in the single-screw extruder; and extruding the solution out of a calender through a die head to cool, take a shape, and be stretched bi-directionally to obtain the reflecting polyester film layer.

10. The method for manufacturing the silver-plated reflecting film of claim 9, wherein the reflecting polyester film layer is foamed during a stretching process after extrusion, and the temperature of processing regions of the single-screw extruder is within a range of 250 C. to 300 C.

11. The method for manufacturing the silver-plated reflecting film of claim 1, wherein the reflecting polyester film layer comprises 5%-25% nanometer modified inorganic filler, and the percentage is a percentage by weight.

12. The method for manufacturing the silver-plated reflecting film of claim 11, wherein the nanometer modified inorganic filler comprises filling particles and modified coating material, the filling particles are selected from one of, or a combination of at least two of, titanium dioxide, barium sulfate, calcium carbonate and zinc oxide, and the modified coating material is silica and/or alumina.

13. The method for manufacturing the silver-plated reflecting film of claim 11, wherein the particle size of the nanometer modified inorganic filler is in a range of 200 nm to 400 nm.

14. The method for manufacturing the silver-plated reflecting film of claim 1, wherein the reflecting polyester film layer has a micro-bubble structure prepared by physical foaming with supercritical carbon dioxide, and the micro-bubbles have a cell size of 1-10 microns and density of 10.sup.8-10.sup.10/cm.sup.3.

15. The method for manufacturing the silver-plated reflecting film of claim 1, wherein the thickness of the reflecting polyester film layer is in a range of 50 m to 150 m, the thickness of the silver-plated layer is in a range of 0.5 m to 1.5 m, and the thickness of the protection layer is in a range of 2 m to 30 m.

16. The method for manufacturing the silver-plated reflecting film of claim 1, wherein the protection layer is a polyester film, a polycarbonate film, a polyethylene film, or a polypropylene film.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0042] FIG. 1 is a structural schematic diagram of a silver-plated reflecting film provided by the present disclosure, wherein 1 represents a protection layer, 2 represents a silver-plated layer, and 3 represents a reflecting polyester film layer.

DETAILED DESCRIPTION

[0043] As shown in FIG. 1, a silver-plated reflecting film (or called silver-plated composite reflecting film, or composite reflecting film) provided by the present disclosure comprises a reflecting polyester film layer 3, a silver-plated layer 2, and a protection layer 1.

[0044] The raw materials used in the present disclosure are common products commercially available in the market, and the nanometer modified inorganic filler that the present disclosure uses is the material commonly used in the field and has common parameter ranges. They can be manufactured by the users themselves or be bought on the market.

[0045] The manufacturing method for the silver-plated composite reflecting film provided by the present disclosure includes the following steps:

[0046] (1) manufacturing a reflecting polyester film layer;

[0047] (2) coating a silver-plated layer on one surface of the reflecting polyester film layer by a vacuum sliver plating method, wherein the vacuum sliver plating methods comprises a vacuum evaporation plating method or a vacuum sputtering silver plating method; and

[0048] (3) applying a protection layer film on the silver-plated layer and obtaining the silver-plated reflecting film.

[0049] In step (2), the silver-plated layer is prepared by the vacuum sputtering silver plating method, which comprises the following steps: [0050] putting 99.99% silver in a target of a sputtering chamber, with Ar as a sputtering gas, a vacuum level of 10-1.010.sup.1 Pa, a working temperature of 850 C. to 1000 C., and a film forming speed of 0.01 mm/min to 5 mm/min; and
forming a silver-plated layer on the reflecting polyester film layer.

[0051] In an embodiment, about vacuum sputtering silver plating method, the working temperature is preferably in a range of 910 C. to 940 C., and the film forming speed is preferably in a range of 0.5 mm/min to 2 mm/min.

[0052] After the step of forming the silver-plated layer on the reflecting polyester film layer, further comprising a step of performing an annealing treatment under nitrogen at the room temperature.

[0053] The silver-plated layer is prepared by the vacuum evaporation plating method, which comprises following steps: [0054] putting 99.99% silver in a crucible of a evaporation chamber, with a vacuum level of 10-1.010.sup.1 Pa, a working temperature of 2000 C. to 2500 C., and a film forming speed of 0.01 mm/min to 5 mm/min; and
forming a silver-plated layer on the reflecting polyester film layer.

[0055] In an embodiment, about the vacuum evaporation plating method, the working temperature is preferably in a range of 2100 C. to 2300 C., and the film forming speed is preferably in a range of 0.5 mm/min to 1 mm/min.

[0056] In step (3), the protection layer film is applied on the silver-plated layer by a dry-type film covering method. The dry-type film covering method comprises the following steps: the protection layer film passing through a heated channel of 90 C.; and pressing the protection layer film onto the silver-plated layer.

[0057] After the step of applying the protection layer film on the silver-plated layer, the method further comprises a step of rolling the silver-plated reflecting film up.

[0058] Various properties of the silver-plated composite reflecting film manufactured according to the abovementioned method were tested using the following method:

[0059] Reflectivity: the ColorQuest XE spectrocolorimeter manufactured by Hunterlab Company was used to test the reflectivity of a silver-plated composite reflecting film of this disclosure by an integrating sphere d/8 structure under the D65 light condition in accordance with Standard GB/T3979-2008. The reflectivity data was the weighted average value of the reflectivity of every wavelength with 10 nm interval between 400-700 nm, and the value corresponded to the energy distribution curve of the D65 light source.

Embodiment 1

[0060] A silver-plated composite reflecting film of this disclosure was manufactured according to the above-descried method. The thickness of the reflecting polyester film layer was 50 m, the thickness of the silver-plated layer was 1.5 m, and the protection layer was polyethylene film with a thickness of 20 m. The related properties of the obtained composite reflecting film are listed in Table 1.

Embodiment 2

[0061] Another silver-plated composite reflecting film of this disclosure was manufactured according to the above-described method. The thickness of the reflecting polyester film layer was 75 m, the thickness of the silver-plated layer was 1.2 m, and the protection layer was polypropylene film with a thickness of 15 m. The related properties of the obtained composite reflecting film are listed in Table 1.

Embodiment 3

[0062] A silver-plated composite reflecting film of this disclosure was manufactured according to the above-described method. The thickness of the reflecting polyester film layer was 100 m, the thickness of the silver-plated layer was 1.0 m, and the protection layer was polyester film with a thickness of 10 m. The related properties of the obtained composite reflecting film are listed in Table 1.

Embodiment 4

[0063] A silver-plated composite reflecting film of this disclosure was manufactured according to the above-described method. The thickness of the reflecting polyester film layer was 150 m, the thickness of the silver-plated layer was 0.5 m, and the protection layer was polycarbonate film with a thickness of 5 m. The related properties of the obtained composite reflecting film are listed in Table 1.

TABLE-US-00001 TABLE 1 Reflectivity of the composite reflecting films of Embodiments 1-4 Embodiments Embod- Embod- Embodiment Item iment 1 iment 2 3 Embodiment 4 Reflectivity 550 nm 99.4 99.2 99.1 99.2 (%)

Embodiment 5

[0064] A silver-plated composite reflecting film of this disclosure was manufactured according to the above-mentioned method. The thickness of the reflecting polyester film layer was 80 m, the thickness of the silver-plated layer was 1.0 m, and the protection layer was polyethylene film with a thickness of 25 m.

[0065] The reflecting polyester film layer contained 5% nanometer modified inorganic filler, the filling particles were selected from titanium dioxide and barium sulfate (with a weight ratio of 1:1), and the modified coating material thereof was silica. The obtained composite reflecting film had a cell size of 1-10 microns, with the density of 10.sup.8-10.sup.9/cm.sup.3, and the related properties are listed in Table 2.

Embodiment 6

[0066] A silver-plated composite reflecting film of the present disclosure was manufactured according to the above-mentioned method. The thickness of the reflecting polyester film layer was 120 m, the thickness of the silver-plated layer was 0.8 m, and the protection layer was polypropylene film with a thickness of 2 m.

[0067] The reflecting polyester film layer contained 25% nanometer modified inorganic filler, the filling particle was selected from titanium dioxide and calcium carbonate (with a weight ratio of 2:1), and the modified coating material thereof was silica and aluminium oxide. The obtained composite reflecting film had a cell size of 1-5 microns, with the density of 10.sup.8-10.sup.9/cm.sup.3, and the related properties are listed in Table 2.

Embodiment 7

[0068] A silver-plated composite reflecting film of the present disclosure was manufactured according to the above-described method. The thickness of the reflecting polyester film layer was 100 m, the thickness of the silver-plated layer was 1.5 m, and the protection layer was polyester film with the thickness of 30 m.

[0069] The reflecting polyester film layer contained 10% nanometer modified inorganic filler, the filling particle was calcium carbonate and the modified coating material thereof wa aluminium oxide. The obtained composite reflecting film had a cell size of 3-10 microns, with the density of 10.sup.9-10.sup.10/cm.sup.3, and the related properties are listed in Table 2.

Embodiment 8

[0070] A silver-plated composite reflecting film of the present disclosure was manufactured according to the above-described method. The thickness of the reflecting polyester film layer was 120 m, the thickness of the silver-plated layer was 0.6 m, and the protection layer was polycarbonate film with the thickness of 15 m.

[0071] The reflecting polyester film layer contained 20% nanometer modified inorganic filler, and the filling particle was zinc oxide, and the modified coating material thereof was silica. The obtained composite reflecting film had a cell size of 1-10 microns, with the density of 10.sup.8-10.sup.10/cm.sup.3, and the related properties are listed in Table 2.

TABLE-US-00002 TABLE 2 Reflectivity of the composite reflecting films of Embodiment 5-8 Embodiment Embodiment Embod- Embod- Embod- Item iment 5 iment 6 iment 7 Embodiment 8 Reflectivity (%) 550 nm 99.3 99.5 98.9 99.4

Embodiment 9

[0072] A silver-plated composite reflecting film of the present disclosure was manufactured according to the above-described method. The thickness of the reflecting polyester film layer was 100 m, the thickness of the silver-plated layer was 1.0 m, and the protection layer was polyethylene film with the thickness of 20 m.

[0073] The reflecting polyester film layer contained 10% nanometer modified inorganic filler, the filling particle was selected from titanium dioxide and barium sulfate (with a weight ratio of 1:1), the modified coating material thereof was silica, and the particle size of the nanometer modified inorganic filler was 200 nm. The temperature of the processing regions of the single-screw extruder was in the range of 250300 C., the cell size and density were adjusted by controlling the proportion of the masterbatch and supercritical carbon dioxide, 0.02 cubic meters of liquid carbon dioxide was added to every kilogram of masterbatch, and the related properties of the obtained silver-plated reflecting film are listed in Table 3.

Embodiment 10

[0074] A silver-plated composite reflecting film of the present disclosure was manufactured according to the above-described method. The thickness of the reflecting polyester film layer was 80 m, and the thickness of the silver-plated layer was 0.8 m, and the protection layer was polypropylene film with the thickness of 15 m.

[0075] The reflecting polyester film layer contained 20% nanometer modified inorganic filler, the filling particle was titanium dioxide, the modified coating material thereof was silica and aluminium oxide, and the particle size of the nanometer modified inorganic filler was 400 nanometers. The temperature of the processing regions of the single-screw extruder was in the range of 250300 C., the cell size and density were adjusted by controlling the proportion of the masterbatch and supercritical carbon dioxide, 0.1 cubic meters of liquid carbon dioxide was added to every kilogram of masterbatch, and the related properties of the obtained silver-plated reflecting film are listed in Table 3.

Embodiment 11

[0076] A silver-plated composite reflecting film of the present disclosure was manufactured according to the above-described method. The thickness of the reflecting polyester film layer was 60 m, the thickness of the silver-plated layer was 1.0 m, and the protection layer was polyester film with the thickness of 10 m.

[0077] The reflecting polyester film layer contained 15% nanometer modified inorganic filler, the filling particle was calcium carbonate, the modified coating material was aluminium oxide, and the particle size of the nanometer modified inorganic filler was 300 nanometers. The temperature of the processing regions of the single-screw extruder was in the range of 250300 C., the cell size and density were adjusted by controlling the proportion of the masterbatch and supercritical carbon dioxide, 0.05 cubic meters of liquid carbon dioxide was added to every kilogram of masterbatch, and the related properties of the obtained silver-plated reflecting film are listed in Table 3.

Embodiment 12

[0078] A silver-plated composite reflecting film of the present disclosure was manufactured according to the above-described method. The thickness of the reflecting polyester film layer was 90 m, the thickness of the silver-plated layer was 0.8 m, and the protection layer was polycarbonate film with the thickness of 5 m.

[0079] The reflecting polyester film layer contained 12% nanometer modified inorganic filler, the filling particle was zinc oxide, the modified coating material thereof was silica, and the particle size of the nanometer modified inorganic filler was 200-400 nanometers. The temperature of the processing regions of the single-screw extruder was 250-300 C., the cell size and density were adjusted by controlling the proportion of the masterbatch and supercritical carbon dioxide, 0.08 cubic meters of liquid carbon dioxide was added to every kilogram of masterbatch, and the related properties of the obtained silver-plated reflecting film are listed in Table 3.

TABLE-US-00003 TABLE 3 Property test table for the composite reflecting films obtained in embodiments 9-12 Embodiments Embodiments Embod- Embod- Embod- Embodiment Item iment 9 iment 10 iment 11 12 Reflectivity 550 nm 99.5 99.4 98.5 99.6 (%)

Comparative Embodiment 1

[0080] A comparative composite reflecting film was manufactured according to the above-mentioned method, the thickness of the reflecting polyester film layer was 120 m, and the protection layer was polycarbonate film with the thickness of 15 m. The difference was the comparative reflecting film did not have a silver-plated layer.

[0081] The comparative reflecting polyester film layer contained 20% nanometer modified inorganic filler, the filling particle was zinc oxide, and the modified coating material thereof was silica. The obtained composite reflecting film had a cell size of 1-10 microns, with the density of 108-1010/cm3. The related properties of the comparative reflecting film are listed in Table 4.

Comparative Embodiment 2

[0082] A comparative composite reflecting film was manufactured according to the above-described method. The thickness of the comparative reflecting polyester film layer was 150 m, the thickness of the silver-plated layer was 1.0 m, and the protection layer was polycarbonate film with the thickness of 20 m.

[0083] The reflecting polyester film layer contained 20% nanometer modified inorganic filler, the filling particle was zinc oxide, and the modified coating material thereof was silica. The difference was the obtained comparative composite reflecting film did not adopt supercritical carbon dioxide for foaming, which did not have the micro-bubble structure of the present disclosure. The related properties of the obtained comparative reflecting film are listed in Table 4.

Comparative Embodiment 3

[0084] A comparative composite reflecting film was manufactured according to the above-mentioned method, the thickness of the reflecting polyester film layer was 100 m, the thickness of the silver-plated layer was 1.0 m, and the protection layer was polycarbonate film with the thickness of 10 m. The difference was the comparative reflecting polyester film layer contained 30% nanometer modified inorganic filler, the filling particle was titanium dioxide, and the modified coating material thereof was silica. In this comparative Embodiment, the content of the nanometer modified inorganic filler was too high. The related properties of the obtained reflecting film are listed in Table 4.

TABLE-US-00004 TABLE 4 Reflectivity of the comparative composite reflecting films Embodiments Comparative Comparative Comparative Item Embodiment 1 Embodiment 2 Embodiment 3 Reflectivity 550 nm 96.3 98.2 98.9 (%)

[0085] As shown in the property test data in Table 1 to Table 4, the composite reflecting films provided by the present disclosure have a higher reflectivity as compared with the reflecting film provided by the comparative Embodiments.

[0086] The above described is just the preferable embodiments of the present disclosure and is not intended to limit the protection scope of the present disclosure. All equivalent alterations and modifications made according to the present disclosure will fall within the scope of the claims of the present disclosure.