Method of making transparent composite articles
Transparent composite articles can be prepared to have one or more electrically-conductive metal-containing patterns. Such method includes steps A), B′), and C), in order. Step A) is providing one or more electrically-conductive metal-containing patterns on a surface of a first substrate. Step B′) is transferring the one or more electrically-conductive metal-containing patterns to a surface of a second substrate thereby providing an electrically-conductive metal-containing pattern on the surface of the second substrate, wherein the second substrate is a transparent laminating film. Step C) is laminating the second substrate with the transferred electrically-conductive metal-containing pattern between two panes of glass to provide the composite article that can be used in various ways, such as antennae in windshields or other transparent structures.
1 . A method for providing a composite article comprising an electrically-conductive metal-containing pattern, the method comprising steps A), B′), and C), in order:
A) providing the electrically-conductive metal-containing pattern disposed directly on a surface of a first substrate film comprising polyethylene terephthalate, polyethylene naphthalate, a mixture of polyethylene terephthalate and polyethylene naphthalate, or a laminate comprising a polyethylene terephthalate film and a polyethylene naphthalate film;
B′) transferring substantially all of the electrically-conductive metal-containing pattern to a surface of a second substrate that is a transparent laminating film consisting essentially of poly(vinyl butyral), by providing the first substrate comprising the electrically-conductive metal-containing pattern in direct contact with the surface of the second substrate under heat, pressure, or heat and pressure, and removing the first substrate from the surface of the second substrate, thereby providing the transferred electrically-conductive metal-containing pattern on the surface of the second substrate; and
C) laminating the second substrate with the transferred electrically-conductive metal-containing pattern between two panes of glass to provide the composite article having an optical transparency of at least 70%.
2 . The method of claim 1 , wherein the composite article has an optical transparency of at least 80%.
3 . The method of claim 1 , wherein step A) comprises steps A-1), A-2), and A-3, in order:
A-1) providing a pattern of a catalytic ink directly on the surface of the first substrate;
A-2) if the catalytic ink comprises a curable polymer precursor, curing the catalytic ink pattern sufficient to form a cured catalytic ink pattern; and
A-3) electrolessly plating a metal onto the cured catalytic ink pattern to form the electrically-conductive metal-containing pattern on the surface of the first substrate.
4 . The method of claim 3 , comprising providing the pattern of catalytic ink using flexographic printing.
5 . The method of claim 3 , wherein the catalytic ink pattern comprises silver nanoparticles and a curable polymer precursor.
6 . The method of claim 1 , wherein the electrically-conductive metal-containing pattern comprises a plurality of features that can be spaced apart or connected.
7 . The method of claim 1 , wherein the electrically-conductive metal-containing pattern comprises copper, gold, aluminum, silver, or platinum, or a combination of two or more of these metals.
8 . The method of claim 1 , wherein the transparent laminating film is in the form of a continuous poly(vinyl butyral) film.
9 . The method of claim 1 for forming a vehicle windshield comprising one or more antenna patterns.
10 . The method of claim 1 , comprising providing two or more electrically-conductive metal-containing patterns in the composite article, by providing two or more of the same or different metallic patterns disposed on the surface of the first substrate, and transferring substantially all of the two or more of the same of different metallic patterns to the surface of the second substrate under heat, pressure, or heat and pressure, and by removing the first substrate from the surface of the second substrate.
11 . The method of claim 1 , further comprising, after step A) and before the transferring step B′), applying a first darkening agent to the electrically-conductive metal-containing pattern provided on the surface of the first substrate.
12 . The method of claim 11 , further comprising, after step B′) and before step C), applying a second darkening agent to the transferred electrically-conductive metal-containing pattern.
13 . A method for providing a composite article comprising an electrically-conductive copper metal-containing pattern, the method comprising, in order:
A-1) providing a pattern of catalytic ink directly on the surface of a first substrate using flexographic printing, the catalytic ink comprising silver nanoparticles or reducible silver ions or reducible copper ions, and a curable polymer precursor, the first substrate being a film comprising polyethylene terephthalate, polyethylene naphthalate, or a mixture of polyethylene terephthalate and polyethylene naphthalate, or the film being a laminate comprising a polyethylene terephthalate film and a polyethylene naphthalate film;
A-2) curing the catalytic ink pattern when the curable polymer precursor is present, sufficient to form a cured catalytic ink pattern;
A-3) electrolessly plating copper metal onto either the catalytic ink pattern comprising the silver nanoparticles or on the cured catalytic ink pattern, to form an electrically-conductive copper metal-containing pattern directly on the surface of the first substrate;
applying a first darkening agent to the electrically-conductive copper metal-containing pattern provided on the surface of the first substate;
B′) transferring substantially all of the electrically-conductive copper metal-containing pattern to a surface of a second substrate that is a transparent laminating film consisting essentially of poly(vinyl butyral), by providing the first substrate comprising the electrically-conductive copper metal-containing pattern in direct contact with the surface of the second substrate under heat, pressure, or heat and pressure, and removing the first substrate from the surface of the second substrate, thereby providing the transferred electrically-conductive copper metal-containing pattern on the surface of the second substrate; and
applying a second darkening agent to the transferred electrically-conductive copper metal-containing pattern; and
C) laminating the second substrate with the transferred electrically-conductive copper metal-containing pattern between two panes of glass to provide the composite article that has an optical transparency of at least 70%.
14 . The method of claim 13 , wherein the first substrate further comprises a primer layer on the surface to which the catalytic ink is applied, and the primer layer comprises one or both of a polymer prepared at least in part from vinyl butyral or poly(2-hydoxyethyl methacrylate).
15 . The method of claim 13 , wherein the catalytic ink comprises the silver nanoparticles.
16 . The method of claim 13 , wherein the catalytic ink comprises the reducible silver ions or reducible copper inks, a silver ion or copper ion reducing agent, and one or more organic solvents.
17 . A method for providing a composite article comprising an electrically-conductive copper metal-containing pattern, the method comprising, in order:
A-1) providing a pattern of catalytic ink on the surface of a first substrate using flexographic printing; and
A-3) electrolessly plating copper metal onto the catalytic ink pattern to form an electrically-conductive copper metal-containing pattern of the surface of the substrate;
applying a first darkening agent to the electrically-conductive copper metal-containing pattern provided on the surface of the first substate;
B′) transferring the electrically-conductive copper metal-containing pattern to a surface of a second substrate, by providing the first substrate comprising the electrically-conductive copper metal-containing pattern in direct contact with the surface of the second substrate, under heat, pressure, or heat and pressure, and removing the first substrate from the surface of the second substrate, thereby providing the electrically-conductive copper metal-containing pattern on the surface of the second substrate, wherein the second substrate is a transparent laminating film comprising poly(vinyl butyral);
applying a second darkening agent to the transferred electrically-conductive copper metal-containing pattern; and
C) laminating the second substrate with the transferred electrically-conductive copper metal-containing pattern between two panes of glass to provide the composite article that has an optical transparency of at least 70%,
wherein the catalytic ink comprises reducible silver ions, a silver (I) reducing agent, a silver nanoparticle dispersing aid, a poly(vinyl butyral) or poly(2-hydroxyethyl methacrylate) binder, and one or more organic solvents.