Hollow glass with prestressed inner suspension membrane and manufacturing method thereof

Abstract

The invention discloses hollow glass with a prestressed inner suspension membrane and a preparation method thereof, and the hollow glass comprises two glass plates which are arranged in parallel and are respectively a first glass plate and a second glass plate; the two layers of inner suspension films are arranged in parallel and located between the two glass plates, and each layer of inner suspension film exerts pretension stress through a tensioning frame and keeps flat; the plurality of spacing frames are used for being arranged between the glass plate and the inner suspension membranes and between the inner suspension membranes to form partitions and jointly enclose a sealed hollow cavity; and the spacing frames are respectively bonded and fixed with the adjacent glass plates or the inner suspension films through sealants. According to the invention, the flatness and the long-term stability of the film layer are obviously improved, the industrialization implementation threshold and the production cost are obviously reduced, and the structural integrity and the sealing durability of the whole unit under the conditions of wind pressure, temperature deformation and long-term load are ensured.

Description

Technical Field

[0001] This invention belongs to the field of building and architectural glass manufacturing, and relates to an insulated glass with a composite structure and its preparation process, specifically an insulated glass with a prestressed inner suspension membrane and its manufacturing method. Background Technology

[0002] Insulating glass, with its excellent heat and sound insulation properties, has become a key material for modern building doors, windows, and curtain walls. Traditional insulating glass consists of two or more panes of glass separated by a spacer and sealed at the edges to form a dry gas cavity. However, its overall performance improvement is limited by the characteristics of the glass and the gas medium itself. In recent years, in pursuit of higher cost-effectiveness, lighter weight, greater energy efficiency, and superior optical effects, innovative designs have emerged in the industry that incorporate functional suspension films (such as Low-E films, sunshade films, and dimming films) within the hollow cavity.

[0003] However, insulated glass units with an inner suspended membrane still face significant technical bottlenecks in terms of large-scale manufacturing and long-term reliability. On the one hand, the supporting and tensioning process of the inner membrane is complex, making it difficult to achieve uniform and efficient prestressing within a closed cavity. This leads to the membrane being prone to relaxation, wrinkling, or deformation, severely affecting visual effects and functional stability. On the other hand, existing tensioning and fixing methods rely heavily on cumbersome assembly or precision components, which are difficult to adapt to the demands of efficient and continuous industrial production, thus hindering the widespread application of this technology. Therefore, there is an urgent need for an innovative structure and process that can ensure the long-term flatness and stability of the inner suspended membrane while being suitable for large-scale manufacturing. Summary of the Invention

[0004] The purpose of this invention is to provide an insulating glass with a prestressed inner suspension membrane and its manufacturing method, so as to overcome the problems of easy wrinkling of the membrane layer, unstable structure and poor optical performance in the prior art, and to achieve a robust structure, excellent optical performance and wrinkle-free long-term use.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0006] An insulating glass unit with a prestressed inner suspension membrane, comprising:

[0007] Two parallel glass plates, namely the first glass plate and the second glass plate;

[0008] Two parallel inner suspension membranes are located between two glass plates. Each inner suspension membrane is pre-stressed and kept flat by a tensioning frame.

[0009] Multiple spacer frames are used to form partitions between the glass plate and the inner suspension membrane, as well as between the inner suspension membranes, and together they enclose a sealed hollow cavity.

[0010] The spacer frame is bonded and fixed to the adjacent glass plate or inner suspension membrane with sealant.

[0011] Furthermore, after assembling one glass plate, one spacer frame, one inner suspension membrane and the tension frame in sequence, the tension frame is removed and the membrane edge is trimmed to form a glass-membrane-frame assembly;

[0012] The two glass-film-frame assemblies are joined together by a central spacer frame, and sealant is applied to the outer joint of the whole to form a structural seal.

[0013] Furthermore, the inner suspension membrane is a transparent polymer plastic film, specifically a PET film, a PC film, or a transparent composite material film.

[0014] Furthermore, the thickness of the inner suspension membrane is 0.5 mm to 1 mm.

[0015] Furthermore, the tensioning frame is a rigid rectangular frame made of aluminum alloy, engineering plastic or glass fiber reinforced composite material, with two adjacent sides on one side serving as fixed frames and two adjacent sides on the other side serving as adjustable frames.

[0016] Furthermore, the adjustable frame is adjustablely connected to the fixed frame via a tension adjustment bolt.

[0017] Furthermore, the outer side of the adjustment frame is provided with a stretchable frame to facilitate the application of tension.

[0018] Furthermore, after the inner suspension membrane is prestressed, it is mechanically fixed to the tensioning frame by pressure strips or by high-strength adhesive.

[0019] The manufacturing method of insulating glass as described above includes the following steps:

[0020] S1. Tensioning and fixing of the inner suspension membrane:

[0021] S1.1 Prepare the tensioning frame and the cleaned inner suspension membrane;

[0022] S1.2 Pre-fixing: The inner suspension membrane is laid flat on the tensioning frame, and its adjacent two sides are fixed with clamps;

[0023] S1.3 Applying pre-tension stress: Through linear stretching operation, tension is applied to the remaining two sides adjacent to the fixed side, so that the membrane is uniformly stretched to the set tension value.

[0024] S1.4 Final Fixation: While maintaining tension, fix each side of the membrane to the tension frame to form a "membrane-frame" assembly;

[0025] S1.5 Trimming: Remove excess membrane edges from the outside of the tension frame;

[0026] S2, Hollow Structure Assembly:

[0027] S2.1 Prepare the first glass plate after cutting, edge grinding and cleaning;

[0028] S2.2 Prepare a spacer frame filled with desiccant and apply a first sealant to both sides of it;

[0029] S2.3, Assembly: The first glass plate, the spacer frame and the "membrane-frame" assembly obtained in step S1 are stacked in sequence and bonded together with the first sealant, wherein the inner suspended membrane faces the inside of the hollow cavity;

[0030] S2.4 Pressing: Apply pressure to the stacked components to ensure that the first sealant makes full contact and forms an effective seal;

[0031] S2.5 Second seal: Apply a second sealant to the outer joints of the first glass plate, the spacer frame, and the tensioning frame;

[0032] S2.6 Curing: After the second sealant has cured, remove the tension frame to obtain the "glass-film-frame" assembly;

[0033] S3. Overall Assembly:

[0034] S3.1: Repeat steps S1-S2 to prepare another "glass-film-frame" assembly;

[0035] S3.2: Connect the two "glass-film-frame" components through the middle spacer frame, and apply a second sealant along the overall outer seam;

[0036] S3.3: Perform final curing to obtain the finished product of inner-suspended membrane insulating glass with a two-glass, two-film, three-cavity structure.

[0037] Furthermore, the first sealant is a butyl hot melt adhesive, and the second sealant is a two-component polysulfide sealant.

[0038] The beneficial effects of this invention are as follows:

[0039] 1) Significantly improved film smoothness and long-term stability:

[0040] By applying uniform and controllable pre-stress to the transparent polymer film through an independent tensioning frame, the film reaches an ideal flat state before installation. This pre-stress effectively counteracts relaxation caused by material creep, temperature changes, and environmental humidity, fundamentally preventing wrinkles or deformation during use and ensuring that the insulated glass maintains excellent optical performance and appearance quality over the long term.

[0041] 2) Strong compatibility with production processes, facilitating industrialization:

[0042] The innovative modular prefabrication method using a "membrane-frame assembly" separates the membrane tension control process from the conventional insulated glass assembly process. This design facilitates modification and integration into existing insulated glass production lines without requiring significant adjustments to equipment and processes, thus significantly lowering the barriers to industrialization and production costs.

[0043] 3) High sealing and reliability:

[0044] A dual-sealing system is employed: the first sealant ensures airtight bonding between the glass plate, spacer frame, and membrane; the second sealant provides structural reinforcement and secondary sealing on the overall perimeter. Combined with the support of the rigid tension frame and spacer frame, this ensures the structural integrity and sealing durability of the entire unit under wind pressure, temperature deformation, and long-term loads, extending its service life.

[0045] 4) Customizable functions, high added value:

[0046] High-polymer transparent plastic films can be made of functional film materials such as PET and PC, and can be further coated, dyed, surface hardened or microstructured, thereby flexibly giving insulated glass a variety of additional functions such as heat insulation, sun shading, UV protection, antistatic, projection display or dimming, expanding the product application scenarios and market competitiveness.

[0047] 5) Lightweight yet with good safety performance

[0048] Compared to traditional hollow or sandwich structures using multi-layered glass, this invention partially replaces the glass layers with a polymer film, significantly reducing overall weight while maintaining good light transmittance, thus lowering the burden of transportation and installation. Simultaneously, the prestressed membrane material and the sealing structure work together to give the product a certain degree of impact resistance and cushioning performance, improving safety during use. Attached Figure Description

[0049] Figure 1 This is a schematic diagram of the insulated glass manufacturing process of the present invention;

[0050] Figure 2 This is a schematic diagram of the tensioning frame of the present invention.

[0051] The markings in the diagram are as follows: 1-First glass plate, 2-Second glass plate, 3-Inner suspension membrane, 4-Tension frame, 41-Fixed frame, 42-Adjusting frame, 43-Stretching frame, 44-Tightening adjustment bolt, 5-Spacer frame, 6-First sealant, 7-Second sealant. Detailed Implementation

[0052] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0053] Example 1:

[0054] An insulating glass unit with a prestressed inner suspension membrane, comprising:

[0055] Two parallel glass plates, namely the first glass plate 1 and the second glass plate 2;

[0056] Two parallel inner suspension membranes 3 are located between two glass plates. Each inner suspension membrane 3 is pre-stressed and kept flat by a tension frame 4.

[0057] Multiple spacer frames 5 are used to form partitions between the glass plate and the inner suspension membrane, as well as between the inner suspension membranes, and together form a sealed hollow cavity; the spacer frames 5 are respectively bonded and fixed to adjacent glass plates or inner suspension membranes by a first sealant 6.

[0058] Furthermore, after assembling one glass plate, one spacer frame, one inner suspension membrane and the tension frame in sequence, the tension frame is removed and the membrane edge is trimmed to form a glass-membrane-frame assembly; two glass-membrane-frame assemblies are joined together by the middle spacer frame, and sealant is applied to the joint on the outer side of the whole to form a structural seal.

[0059] In this embodiment, the inner suspension membrane is a PET film, PC film, or other transparent composite material film with a thickness of 0.5 mm to 1 mm.

[0060] In this embodiment, the tensioning frame is a rigid rectangular frame made of aluminum alloy, engineering plastic, or glass fiber reinforced composite material. Two adjacent sides on one side serve as fixed frames, and two adjacent sides on the other side serve as adjustable frames. The adjustable frames are adjustablely connected to the fixed frames via tension adjustment bolts (the bolts are loosened during tensioning and tightened after tensioning). To facilitate the application of tension, a tensioning frame can be provided on the outside of the adjustable frames. After applying pre-tension stress to the inner suspension membrane, it is then mechanically fixed to the tensioning frame using pressure strips or bonded with high-strength adhesive.

[0061] Example 2:

[0062] The method for manufacturing a 1000mm × 1500mm double-glazed, double-film, triple-cavity insulated glass unit with a pre-stressed inner suspension membrane is as follows:

[0063] (1) Material preparation:

[0064] Two pieces of 5mm thick tempered glass are used as the first glass plate 1 and the second glass plate 2, respectively.

[0065] Two aluminum alloy tensioning frames, each 30mm wide;

[0066] Two 0.5mm thick transparent PC films are used as high-polymer transparent plastic film 3, and are pre-cleaned;

[0067] Two 12mm wide aluminum alloy spacer frames 5, filled with 3A molecular sieve desiccant;

[0068] The first sealant 6 is a butyl hot melt adhesive;

[0069] The second sealant 7 is a two-component polysulfide sealant.

[0070] (2) Membrane tensioning and “membrane-frame” assembly fabrication (tensioning of two membranes separately):

[0071] ① In a Class 10,000 cleanroom, lay a PC film flat on a tension frame.

[0072] ② Use the frame's built-in clamps to secure the top and left sides of the membrane.

[0073] ③ Using pneumatic or manual linear stretching, apply uniform tension to the bottom and right sides of the membrane to control the membrane surface tension value to 150 N / m. This can be monitored in real time by a laser flatness sensor to ensure the overall flatness of the membrane surface.

[0074] ④ After the tension stabilizes, stainless steel pressure strips are used to lock the four sides of the membrane into the dovetail groove of the frame to achieve permanent fixation.

[0075] ⑤ Remove excess membrane edges from the outer side of the frame to complete the first "membrane-frame" assembly. Repeat the above steps to prepare the second "membrane-frame" assembly.

[0076] (3) Assemble the pieces to form a semi-finished unit:

[0077] ① Place the first glass plate horizontally on the assembly worktable.

[0078] ② Place a spacer frame coated with butyl rubber.

[0079] ③ Carefully close the first “membrane-frame” assembly so that the PC membrane faces the inside of the spacer frame.

[0080] ④ Use a press to press evenly for 10 seconds at a pressure of 0.05MPa to ensure that the first sealant is fully bonded.

[0081] ⑤ Apply two-component polysulfide sealant as a second sealant to the outer joint of the first glass plate, the spacer frame and the tensioning frame.

[0082] ⑥ Curing for 24 hours in an environment with a temperature of 23±2℃ and a relative humidity of 50%±10% yields the first semi-finished unit ("glass-film-frame" assembly).

[0083] ⑦ Repeat steps ①-⑥ to prepare the second semi-finished unit using the second glass plate and the second "membrane-frame" assembly.

[0084] (4) Overall connection and final sealing:

[0085] ① Align the spacer frames of the two semi-finished units face to face and ensure overall alignment.

[0086] ② Apply two-component polysulfide sealant along the outer perimeter of the joint after the butt joint to form a continuous and uniform second sealing layer.

[0087] ③ Under the same temperature and humidity conditions, the final curing is carried out for 48 hours to obtain a finished insulated glass product with a prestressed inner suspension membrane and a three-cavity structure consisting of two panes of glass, two films, and three cavities.

[0088] (5) Inspection:

[0089] The product has been tested and found to have a dew point below -60℃, and all cavities exhibit good airtightness. Both PC films have smooth, wrinkle-free surfaces, and their optical performance is uniform and stable, meeting design and usage requirements.

[0090] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the above embodiments do not limit the scope of protection of the present invention in any way, and all technical solutions obtained by equivalent substitution or other means fall within the scope of protection of the present invention. Parts not covered in this invention are the same as or can be implemented using existing technology.

Claims

1. A type of insulating glass with a prestressed inner suspension membrane, characterized in that, include: Two parallel glass plates, namely the first glass plate and the second glass plate; Two parallel inner suspension membranes are located between two glass plates. Each inner suspension membrane is pre-stressed and kept flat by a tensioning frame. Multiple spacer frames are used to form partitions between the glass plate and the inner suspension membrane, as well as between the inner suspension membranes, and together they enclose a sealed hollow cavity. The spacer frame is bonded and fixed to the adjacent glass plate or inner suspension membrane with sealant.

2. The insulating glass with a prestressed inner suspension membrane according to claim 1, characterized in that, After assembling a glass plate, a spacer frame, an inner suspension membrane, and a tension frame in sequence, the tension frame is removed and the membrane edge is trimmed to form a glass-membrane-frame assembly. The two glass-film-frame assemblies are joined together by a central spacer frame, and sealant is applied to the outer joint of the whole to form a structural seal.

3. The insulating glass with a prestressed inner suspension membrane according to claim 1, characterized in that, The inner suspension membrane is a high-molecular transparent plastic film, specifically a PET film, a PC film, or a transparent composite material film.

4. The insulating glass with a prestressed inner suspension membrane according to claim 1, characterized in that, The thickness of the inner suspension membrane is 0.5 mm to 1 mm.

5. The insulating glass with a prestressed inner suspension membrane according to claim 1, characterized in that, The tensioning frame is a rigid rectangular frame made of aluminum alloy, engineering plastic or glass fiber reinforced composite material, with two adjacent sides on one side serving as fixed frames and two adjacent sides on the other side serving as adjustable frames.

6. The insulating glass with a prestressed inner suspension membrane according to claim 5, characterized in that, The adjustable frame is adjustablely connected to the fixed frame via a tension adjustment bolt.

7. The insulating glass with a prestressed inner suspension membrane according to claim 5, characterized in that, The outer side of the adjustment frame is provided with a stretchable frame to facilitate the application of tension.

8. The insulating glass with a prestressed inner suspension membrane according to claim 1, characterized in that, After the inner suspension membrane is prestressed, it is mechanically fixed to the tensioning frame by pressure strips or by high-strength adhesive.

9. A method for manufacturing insulating glass as described in any one of claims 1 to 8, characterized in that, Includes the following steps: S1. Tensioning and fixing of the inner suspension membrane: S1.1 Prepare the tensioning frame and the cleaned inner suspension membrane; S1.2 Pre-fixing: The inner suspension membrane is laid flat on the tensioning frame, and its adjacent two sides are fixed with clamps; S1.3 Applying pre-tension stress: Through linear stretching operation, tension is applied to the remaining two sides adjacent to the fixed side, so that the membrane is uniformly stretched to the set tension value. S1.4 Final Fixation: While maintaining tension, fix each side of the membrane to the tension frame to form a "membrane-frame" assembly; S1.5 Trimming: Remove excess membrane edges from the outside of the tension frame; S2, Hollow Structure Assembly: S2.1 Prepare the first glass plate after cutting, edge grinding and cleaning; S2.2 Prepare a spacer frame filled with desiccant and apply a first sealant to both sides of it; S2.3, Assembly: The first glass plate, the spacer frame and the "membrane-frame" assembly obtained in step S1 are stacked in sequence and bonded together with the first sealant, wherein the inner suspended membrane faces the inside of the hollow cavity; S2.4 Pressing: Apply pressure to the stacked components to ensure that the first sealant makes full contact and forms an effective seal; S2.5 Second seal: Apply a second sealant to the outer joints of the first glass plate, the spacer frame, and the tensioning frame; S2.6 Curing: After the second sealant has cured, remove the tension frame to obtain the "glass-film-frame" assembly; S3. Overall Assembly: S3.1: Repeat steps S1-S2 to prepare another "glass-film-frame" assembly; S3.2: Connect the two "glass-film-frame" components through the middle spacer frame and apply a second sealant along the overall outer seam; S3.3: Perform final curing to obtain the finished product of inner-suspended membrane insulating glass with a two-glass, two-film, three-cavity structure.

10. The method for manufacturing insulating glass according to claim 9, characterized in that, The first sealant is butyl hot melt adhesive, and the second sealant is two-component polysulfide sealant.

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