A multi-layer laminated soundproof glass and a splicing process thereof

Abstract

This invention belongs to the field of soundproof glass processing technology, specifically relating to a multi-layer laminated soundproof glass and its lamination process. The multi-layer laminated soundproof glass is composed of multiple layers of glass sheets alternately laminated with sound-insulating films. The thickness of the glass sheets gradually increases from the outside to the inside, with a thickness difference of at least 1 mm between adjacent glass sheets. The sound-insulating film gradually increases in damping from the outside to the inside, forming a gradient damping structure. For 3-layer or 4-layer glass structures, materials such as PVB film, SGP ionic interlayer film, and modified butyl rubber sound-insulating film with corresponding layer numbers are selected. The lamination process employs segmented temperature and pressure controlled curing and stepped gradient slow cooling. This invention effectively staggers the resonance peaks of each glass layer, solving defects such as residual bubbles, interlayer misalignment, and stress cracking in existing processes. The resulting product has a weighted sound insulation Rw of 38-45 dB, a yield rate >98%, and is controllable, highly versatile, and suitable for industrial mass production in high-end buildings and quiet environments.

Description

Technical Field

[0001] This invention belongs to the field of soundproof glass processing technology, specifically relating to a multi-layer laminated soundproof glass and its lamination process. Background Technology

[0002] The information disclosed in this background section is intended only to enhance understanding of the overall background of the invention and is not necessarily to be construed as an admission or in any way implying that such information constitutes prior art known to those skilled in the art.

[0003] With the acceleration of urbanization, traffic noise, industrial noise, and residential noise have seriously affected people's living and working environments. As an effective noise control method, soundproof glass is increasingly widely used in the construction field. Traditional soundproof glass is mostly a double-layer laminated structure, relying solely on a single layer of PVB (polyvinyl butyral) or SGP (ionomer cemented carbide) film to provide damping. Its sound insulation performance has obvious defects, especially in the mid-to-low frequency (100–500Hz) range, where the sound insulation is low and it is difficult to effectively block low-frequency noise from traffic, industry, etc., thus failing to meet the sound insulation requirements of high-end buildings and quiet places.

[0004] To improve sound insulation performance, the industry has gradually begun to explore multi-layer laminated sound insulation structures that combine three or more layers of glass with multiple layers of interlayer film. However, existing lamination processes mostly follow the traditional one-step autoclave lamination method for double-layer laminated glass, which is difficult to adapt to the lamination requirements of multi-layer structures and is prone to a series of technical problems: First, the gaps between the layers in multi-layer structures are large, and air cannot be completely expelled during the one-step lamination process, resulting in air bubbles inside the finished glass, affecting sound insulation performance and appearance quality; Second, when multiple glass sheets are stacked, misalignment is prone to occur, and the cumulative thickness difference will lead to uneven flow of the interlayer film, resulting in defects such as local missing adhesive and wrinkles; Third, the instantaneous increase in temperature and pressure inside the autoclave will cause excessive temperature difference between the inner and outer glass layers, generating large internal stress, which may lead to glass cracking or edge delamination; Fourth, the damping effect of single-layer or multi-layer interlayer film with the same modulus is limited. Even if the number of glass and interlayer film layers is increased, the improvement in sound insulation is relatively gradual and cannot achieve a step-by-step enhancement of sound insulation performance.

[0005] Currently, the industry lacks a systematic and innovative lamination process specifically for multi-layer (3 layers and above) laminated soundproof glass. Existing processes are unable to overcome the bottlenecks in the industrial production of multi-layer soundproof glass, thus limiting its widespread application. Therefore, developing an innovative lamination process that can solve the above-mentioned defects and improve the lamination quality and sound insulation performance of multi-layer laminated soundproof glass has significant practical importance and application value. Summary of the Invention

[0006] To address the problems existing in the prior art, the present invention aims to overcome the technical defects of existing multi-layer laminated soundproof glass lamination processes, such as air bubbles, interlayer misalignment, stress cracking, and poor sound insulation performance. It provides a multi-layer laminated soundproof glass lamination process that is rationally designed, highly controllable, and has a high yield rate. This process can achieve stable lamination of three or more layers of glass, producing multi-layer laminated soundproof glass with no interlayer air bubbles, high alignment accuracy, uniform adhesive layer, and excellent sound insulation performance, meeting the sound insulation needs of high-end buildings and quiet environments.

[0007] To achieve the above-mentioned technical effects, the present invention provides the following technical solution: In one aspect, a multi-layer laminated soundproof glass is provided, which is made of multiple layers of glass sheets bonded together, and the thickness of the sheets gradually increases from the outside to the inside.

[0008] Existing multi-layered soundproof glass, where glass of equal thickness resonates at the same frequency, results in noticeable pits in sound insulation. This invention uses glass sheets with gradient thicknesses for bonding, ensuring that each layer vibrates at a different frequency, leading to a smoother sound insulation curve. In this solution, each layer of glass should be made of the same material, such as float glass, tempered glass, semi-tempered glass, or ultra-clear glass. The thickness of the glass sheets is 4-12mm, with the inner glass being at least 1mm thicker than the adjacent outer glass. For even better results, the thickness difference between adjacent glass sheets is 2mm or more, resulting in a more significant staggered effect.

[0009] In one embodiment verified by the present invention, the soundproof glass is made of three layers of glass sheets bonded together, with thicknesses of 5mm+6mm+5mm, or 5mm+7mm+5mm, or 6mm+7mm+6mm, or 6mm+8mm+6mm, or 4mm+5mm+4mm respectively.

[0010] In another embodiment, the soundproof glass is made of four layers of glass sheets bonded together, with thicknesses of 5mm+6mm+8mm+5mm, or 5mm+6mm+7mm+5mm, or 6mm+8mm+10mm+6mm, or 5mm+6mm+7mm+5mm, or 5mm+7mm+9mm+5mm.

[0011] In addition, the raw materials for preparing the above-mentioned soundproof glass also include soundproof film, which is placed between the original glass sheets. The soundproof film gradually increases in damping from the outside to the inside. Feasible soundproof film materials include, but are not limited to, polyvinyl butyral (PVB) film, SGP ionic interlayer film, modified butyl rubber soundproof film, nitrile rubber (NBR) soundproof film, and thermoplastic elastomer TPE / TPV soundproof film.

[0012] In one embodiment, when the glass has three layers, two layers of sound-insulating film are selected: the first layer is a transparent modified butyl rubber sound-insulating film with a thickness of 0.8–1.2 mm and a modulus of 10–15 MPa, whose main function is to absorb low- and mid-frequency noise and improve the damping and vibration reduction effect; the second layer is an SGP ionic interlayer film with a thickness of 0.76 mm and a modulus of 80–120 MPa, whose main function is to enhance the structural strength and bonding stability of the laminated glass and prevent interlayer debonding.

[0013] When the glass has four layers, a three-layer sound insulation film is selected: the first layer is a soft PVB sound insulation film with a thickness of 0.38 mm and a modulus of 20–30 MPa; the second layer is a transparent modified butyl rubber sound insulation film with a thickness of 0.8–1.2 mm and a modulus of 10–15 MPa; and the third layer is an SGP ionomer interlayer with a thickness of 0.76 mm and a modulus of 80–120 MPa, which further optimizes the damping gradient and improves the sound insulation performance across the entire frequency band.

[0014] Secondly, a lamination process for the multilayer laminated soundproof glass described in the first aspect is provided, comprising the following steps: Select a sound-insulating film based on the chosen glass sheet, assemble the sheets, transfer them to a vacuum bag and preheat for initial bonding to obtain a pre-assembled sheet; transfer the pre-assembled sheet into an autoclave and cure it through segmented temperature and pressure control, then slowly cool it through step-down cooling, and seal the edges to obtain the final product; The segmented temperature and pressure control method is as follows: The first stage involves controlling the heating rate inside the autoclave at 1–2℃ / min, raising the temperature to 70–85℃ (T1), while simultaneously introducing compressed air into the autoclave to raise the pressure inside to 0.4–0.6MPa (P1), and maintaining this temperature and pressure for 10–15min (t1). The purpose of this stage is to slowly soften each layer of sound insulation film, fully wet the glass surface, and allow any remaining microbubbles between the layers to slowly migrate to the glass edge for easy removal. The second stage: medium-temperature and medium-pressure fusion stage: control the heating rate in the autoclave at 2–3℃ / min, raise the temperature to 95–110℃ (T2), and at the same time raise the pressure in the autoclave to 0.8–1.1MPa (P2), and maintain this temperature and pressure for 15–20min (t2); the purpose of this stage is to fuse the multiple layers of sound insulation films with different moduli together, eliminate the gaps between the layers, achieve complete bonding between each layer of film and glass, and further remove residual air bubbles; The third stage: High temperature and high pressure setting stage: The heating rate inside the autoclave is controlled at 1–2℃ / min, raising the temperature to 125–140℃ (T3), while the pressure inside the autoclave is raised to 1.2–1.5MPa (P3), and this temperature and pressure are maintained for 30–45min (t3). The purpose of this stage is to fully cross-link and cure the sound insulation film, ensuring the bonding strength between each layer of glass and the film, while improving the structural stability and safety performance of the laminated glass.

[0015] The stepped cooling method is as follows: First stage: Reduce the temperature inside the autoclave from 140℃ to 110℃, controlling the cooling rate at 2–3℃ / min, while keeping the pressure inside the autoclave constant throughout the process; Second stage: Reduce the temperature inside the autoclave from 110℃ to 70℃, control the cooling rate at 1–2℃ / min, and keep the pressure inside the autoclave constant throughout the process; Third stage: After the temperature inside the autoclave drops below 70°C, stop the pressure holding and allow it to cool naturally to room temperature (20–25°C).

[0016] The curing stage of the above-mentioned lamination process adopts a progressive process of low temperature and low pressure, medium temperature and medium pressure, and high temperature and high pressure. This makes the rheological behavior and thermal curing behavior of the adhesive film controllable, synchronous and uniform. It can effectively avoid the instantaneous flow and bubble generation of the adhesive film caused by sudden changes in temperature and pressure. At the same time, it can also increase the full wetting of the adhesive film on the glass surface, making the bonding strength stronger.

[0017] Stepped cooling, by controlling the cooling rate, allows the structure to slowly release internal stress, achieving stress homogenization. Using this method results in better thermal shrinkage matching between the adhesive film and the original glass sheet, reducing the likelihood of edge detachment, leading to a higher flatness of the assembled product and making it less prone to deformation over long-term use.

[0018] Furthermore, the specific steps of the lamination process described in the second aspect above are as follows: S1. Select a clean and dry glass sheet for plasma activation treatment, select a sound-insulating film and cut it according to the size of the sheet; the parameters of the plasma activation are as follows: process for 30–60 seconds at a power of 80–120W; S2. In a clean room, the original glass sheet and the sound insulation film are laid out in sequence and then assembled. The glass sheet is then placed in a vacuum bag and vacuumed at -0.090 to -0.095 MPa. The whole bag is preheated by holding the pressure at 50–65℃ for 15–25 minutes to obtain the pre-assembled sheet. S3. Transfer the pre-assembled sheet obtained in S2 into an autoclave and cure it in stages with controlled temperature and pressure as described above. During the curing process, control the temperature fluctuation in the autoclave to ≤±1℃ and the pressure fluctuation to ≤±0.05MPa. Then, slowly cool it through the above-mentioned step cooling method to obtain the assembled sheet product. S4. Clean the edges of the assembled product, and then seal the edges with butyl sealant and structural adhesive. The thickness of the butyl sealant is 1.5–2.0 mm, the thickness of the structural adhesive is 2.0–2.5 mm, and the sealing width is 5–8 mm.

[0019] In S1 above, the purpose of plasma activation is to enhance the surface activity of the glass and strengthen the adhesion to the sound insulation film. After the pretreatment is completed, the glass is placed in a Class 1000 cleanroom for later use to avoid secondary contamination.

[0020] In S2 above, the lamination method is as follows: the pre-treated glass sheet is placed on the positioning fixture, the first layer of sound-insulating film is laid, and the film is flattened by a vacuum leveling device to ensure that the film is completely adhered to the surface of the glass sheet without wrinkles or bubbles; the second glass sheet is then placed, and the second glass sheet is precisely positioned by a CCD vision alignment system to ensure that the misalignment between the second and first glass sheets is ≤0.2mm; the second layer of sound-insulating film is laid on the upper surface of the second glass sheet, and the film is flattened again by a vacuum leveling device; the above alignment and leveling operations are repeated to form a multi-layer laminated pre-laminated semi-finished product, and the pre-laminated semi-finished product is placed into a vacuum bag, sealed, and then vacuum-treated.

[0021] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention first provides a multi-layer laminated soundproof glass, employing a gradient modulus multi-layer damping film system. The thickness of the original glass sheets is gradient-distributed, and the soundproofing films placed between the original sheets also adopt an alternating arrangement to form a damping gradient structure. This structural design effectively staggers the resonance peaks of each glass layer, significantly improving mid-to-low frequency sound insulation performance. The resulting multi-layer laminated soundproof glass achieves a weighted sound insulation Rw of 38–45 dB, which is 8–12 dB higher than that of traditional double-layer laminated glass, effectively isolating mid-to-low frequency noise from traffic, industry, etc.

[0022] 2. This invention also provides the above-mentioned lamination process for multi-layer laminated soundproof glass, namely the innovative process of "step-by-step vacuum lamination + segmented high-pressure curing". By pre-pressing the vacuum to remove interlayer air in advance, and combined with the segmented heating and pressurizing curing system, the adhesive film gradually flows and is fully wetted, which effectively solves the problems of residual air bubbles, wrinkling of adhesive film, and lack of adhesive in the multi-layer lamination process. The air bubble rate of the laminated product is <0.5%, and the yield is >98%.

[0023] During the pre-assembly stage, the present invention also employs a CCD vision alignment system to ensure that the misalignment of multiple glass pieces is ≤0.2mm, avoiding uneven film flow caused by the accumulation of thickness differences; at the same time, a gradient slow cooling process is adopted to effectively release the internal stress generated during the assembly process, prevent glass cracking and edge debonding, and improve the structural stability and service life of the assembled glass.

[0024] The lamination process is highly controllable and easy to operate, requiring no complex special equipment. It is compatible with various multi-layer laminated structures such as 3-glass 2-bonded and 4-glass 3-bonded, making it extremely versatile. It can achieve industrialized mass production, reduce production costs, and promote the widespread application of multi-layer laminated soundproof glass. Attached Figure Description

[0025] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0026] Figure 1 This is a schematic diagram of the structure of the multilayer laminated soundproof glass described in Example 1; Figure 2 This is a side view of the structure of the multilayer laminated soundproof glass described in Example 1; Figure 3 This is a schematic diagram of the sealing structure of the multilayer laminated soundproof glass described in Example 1; Figure 4 This is a schematic diagram of the structure of the multilayer laminated soundproof glass described in Example 2; The above Figures 1-4 In this context, G1, G2, G3 and G4 represent tempered glass of different thicknesses, A1 represents SGP ionomer interlayer, A2 represents transparent modified butyl rubber sound insulation film, A3 represents soft PVB sound insulation film, and B1 represents sealing edge. Detailed Implementation

[0027] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0028] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0029] In the context of this invention, the word "comprising" is considered to mean "particularly including". It should not be interpreted as "consisting of only".

[0030] In the description of this invention, it should be understood that the term "and / or" describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. The symbol " / " in this document indicates that the related objects are in an "or" relationship; for example, A / B means A or B.

[0031] In the description of embodiments of the present invention, the words "exemplary" or "for example" are used to indicate that they are examples, illustrations, or descriptions. Any embodiment or design that is described as "exemplary" or "for example" in the embodiments of the present invention should not be construed as being more preferred or advantageous than other embodiments or design. Specifically, the use of the words "exemplary" or "for example" is intended to present the relevant concepts in a specific manner.

[0032] In the description of the embodiments of the present invention, unless otherwise stated, "a plurality of" means two or more.

[0033] To enable those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention will be described in detail below with reference to specific embodiments and comparative examples.

[0034] Example 1 In this embodiment, a multi-layer laminated soundproof glass is provided, which is composed of three layers of tempered glass bonded together, numbered G1, G2, and G3 from the outside in. The thicknesses of G1, G2, and G3 are 6mm, 8mm, and 6mm respectively. A transparent modified butyl rubber soundproof membrane is used between G1 and G2, and an SGP ionomer cemented carbide interlayer is used between G2 and G3. During installation, G1 is positioned closer to the outside, and G3 is positioned closer to the inside.

[0035] This embodiment also provides a lamination process for the above-mentioned soundproof glass, which specifically includes the following steps: S1. Original glass screening and processing: Select 3 pieces of tempered glass with a flatness error ≤0.1mm / m, no scratches and no damage; use anhydrous ethanol and deionized water at a volume ratio of 1:3 to prepare a cleaning solution, clean the glass twice, then dry it in a 65℃ hot air drying equipment for 12 minutes, and then put it into a plasma cleaner for 45 seconds of plasma activation treatment at 100W power. After the treatment, put it into a Class 1000 clean room for later use.

[0036] S2. Selection and cutting of sound insulation film: Select sound insulation film. The first layer is a transparent modified butyl rubber sound insulation film with a thickness of 1.0 mm and a modulus of 12 MPa. The second layer is an SGP ionomer interlayer film with a thickness of 0.76 mm and a modulus of 100 MPa. Cut precisely according to the glass size with a cutting error of ≤0.1 mm and store in a Class 1000 clean room for later use.

[0037] S3. Cleanroom Pre-assembly and Vacuum Pre-compression Shaping: In a Class 1000 cleanroom, G1 is placed on a positioning fixture, and the first layer of transparent modified butyl rubber sound insulation film is laid and vacuum-flattened; G2 is placed and aligned using CCD vision to ensure misalignment ≤0.2mm; the second layer of SGP ionic interlayer film is laid and vacuum-flattened; G3 is placed, precisely aligned, and then transferred into a vacuum bag, vacuumed to -0.095MPa, and held under pressure for 20 minutes in a preheating device at 60℃ to complete the pre-compression shaping and obtain the pre-assembled sheet.

[0038] S4. Segmented Autoclave Curing: Place the pre-assembled sheet into the autoclave. First stage: heat to 80℃ at 1.5℃ / min, pressure to 0.5MPa, hold for 12min; Second stage: heat to 105℃ at 2.5℃ / min, pressure to 1.0MPa, hold for 18min; Third stage: heat to 135℃ at 1.5℃ / min, pressure to 1.4MPa, hold for 40min. Temperature fluctuation ≤ ±1℃, pressure fluctuation ≤ ±0.05MPa throughout the process. After curing, in the first stage, cool to 110℃ at 2.5℃ / min, hold for pressure; in the second stage, cool to 70℃ at 1.5℃ / min, hold for pressure; in the third stage, allow natural cooling to 23℃, depressurize, and remove the assembled sheet.

[0039] S5. Edge Sealing: Clean the edges of the assembled pieces and apply double-layer sealing with butyl sealant (1.8mm thick) + structural adhesive (2.2mm thick), with a sealing width of 6mm. Figure 3 (B1), cured for 36 hours; quality inspection showed that the assembled product had no bubbles, no delamination, no misalignment, a bonding strength of 2.0MPa, a light transmittance of 88%, a weighted sound insulation Rw≈42dB, and the ball impact performance met the GB / T 9963-2015 standard, and the test was qualified.

[0040] Example 2 In this embodiment, another type of multi-layer laminated soundproof glass is provided, which is composed of four layers of tempered glass bonded together, numbered G1, G2, G3, and G4 from the outside in. The thicknesses of G1, G2, G3, and G4 are 5mm, 6mm, 8mm, and 5mm, respectively. A flexible PVB sound insulation membrane is used between G1 and G2, a transparent modified butyl rubber sound insulation membrane is used between G2 and G3, and an SGP ionomer interlayer is used between G3 and G4. During installation, G1 is positioned closer to the outside, and G4 is positioned closer to the inside.

[0041] The specific steps of the assembly process for this soundproof glass are as follows: S1. Select 4 pieces of tempered glass with a flatness error of ≤0.1mm / m, free from scratches and damage; prepare a cleaning solution using anhydrous ethanol and deionized water at a volume ratio of 1:3, perform two cleanings on the glass, then dry it in a 60℃ hot air drying device for 15 minutes, and then place it in a plasma cleaner for 60 seconds at 80W power. After the treatment is completed, place it in a Class 1000 cleanroom for later use.

[0042] S2. Sound Insulation Film Selection and Cutting: Select a 3-layer sound insulation film. The first layer is a soft PVB sound insulation film with a thickness of 0.38mm and a modulus of 25MPa. The second layer is a transparent modified butyl rubber sound insulation film with a thickness of 0.8mm and a modulus of 10MPa. The third layer is an SGP ionomer interlayer film with a thickness of 0.76mm and a modulus of 80MPa. Cut precisely according to the glass size, with a cutting error of ≤0.1mm, and store in a Class 1000 cleanroom for later use.

[0043] S3. Cleanroom Pre-assembly and Vacuum Pre-compression Shaping: In a Class 1000 cleanroom, G1 is placed on a positioning fixture, the first layer of soft PVB sound insulation film is laid, and vacuum leveled; G2 is placed and aligned using CCD vision to ensure misalignment ≤0.2mm; the second layer of transparent modified butyl rubber sound insulation film is laid, and vacuum leveled; G3 is placed, and after alignment, the third layer of SGP ionic interlayer film is laid, and vacuum leveled; G4 is placed, precisely aligned, and placed in a vacuum bag, vacuumed to -0.090MPa, and held under pressure for 25 minutes in a preheating device at 55℃ to complete the pre-compression shaping and obtain the pre-assembled sheet.

[0044] S4. Segmented Autoclave Curing: Place the pre-assembled sheet into the autoclave. First stage: heat to 75℃ at 1℃ / min, pressure to 0.4MPa, hold for 15min; Second stage: heat to 95℃ at 2℃ / min, pressure to 0.8MPa, hold for 20min; Third stage: heat to 125℃ at 1℃ / min, pressure to 1.2MPa, hold for 45min. Temperature fluctuation ≤ ±1℃, pressure fluctuation ≤ ±0.05MPa throughout the process. After curing, in the first stage, cool to 110℃ at 2℃ / min, hold for pressure; in the second stage, cool to 70℃ at 1℃ / min, hold for pressure; in the third stage, allow natural cooling to 20℃, depressurize, and remove the assembled sheet.

[0045] S5. Edge Sealing: Clean the edges of the assembled pieces, and apply double-layer sealing with butyl sealant (1.5mm thick) + structural adhesive (2.0mm thick), with a sealing width of 5mm, and cure for 48 hours; quality inspection shows that the finished assembled pieces are free of bubbles, delamination, and misalignment, with a bonding strength of 1.9MPa, light transmittance of 86%, weighted sound insulation Rw≈45dB, and drop ball impact performance meets GB / T 9963-2015 standard, and the test is qualified.

[0046] Comparative Example 1 In this comparative example, a multilayer laminated soundproof glass is provided. The difference from Example 1 is that its preparation method uses a direct heating and curing method, specifically step S4 as follows: Place the pre-assembled sheet into an autoclave, heat it to 135℃ at a rate of 2℃ / min, increase the pressure to 1.4MPa, and hold the pressure for 70min; throughout the process, control the temperature fluctuation ≤±1℃ and the pressure fluctuation ≤±0.05MPa. After curing, cool it down to 23℃ at a rate of 1.5℃ / min, release the pressure, and remove the assembled sheet.

[0047] Comparative Example 2 In this comparative example, another type of multilayer laminated soundproof glass is provided. The difference from Example 1 is that the thicknesses of G1, G2, and G3 are 8mm, 8mm, and 8mm respectively; the other settings are the same as in Example 1.

[0048] Sound insulation performance test The test was conducted in accordance with GB / T 8485-2022 "Classification and Test Methods for Airborne Sound Insulation Performance of Building Doors, Windows, Glass and Sunshade Products", using a standard reverberation chamber-anechoic chamber dual-chamber sound insulation testing system. The testing environment was controlled under uniform conditions: ambient air temperature 23℃±2℃, relative humidity 45%~55%, with no additional airflow disturbances or background noise interference indoors. The effective test frequency band covered 100Hz~5000Hz, fully covering all operating conditions including low-frequency noise from urban traffic, mid-frequency noise from daily life, and high-frequency noise from outdoor equipment. The results are shown in Table 1 below. Table 1. Comparison of sound insulation effects of multilayer soundproof glass in the examples and comparative examples. Example 2 uses four layers of tempered glass combined with a three-layer gradient modulus composite sound insulation membrane of PVB, modified butyl rubber, and SGP to form a multi-layer damping energy dissipation sound insulation system. Compared with the three-layer structure of Example 1, it further weakens the sound energy transmission path and achieves a weighted sound insulation of 45dB, which is the best sound insulation solution among the four groups of samples. It can be adapted to harsh sound insulation scenarios such as high-noise street-facing buildings and the surrounding enclosure of machine rooms.

[0049] Example 1 uses a gradient thickness design of 6mm / 8mm / 6mm. Compared with the symmetrical structure of 8mm uniform thickness in Comparative Example 2, the sound insulation effect shows that the gradient thickness design can effectively break the inherent resonance effect of glass at the same frequency, weaken the structural resonance sound insulation trough induced by low-frequency traffic noise, and the low-frequency sound insulation performance is significantly better than that of uniform thickness homogeneous glass arrangement. It is more adaptable to the low-frequency noise conditions of urban traffic flow.

[0050] Examples 1 and 2 employ a controllable curing method involving segmented heating and pressurization followed by segmented gradient cooling and pressure stabilization. This results in a uniform transition of the adhesive layer modulus, no residual internal stress at the interface, and dense interlayer bonding without any hidden defects. In contrast, Comparative Example 1's one-time rapid high-temperature and high-pressure curing easily leads to uneven cross-linking between the inner and outer layers of the film, leaving micro-voids at the interface. This directly results in a significant decrease in overall sound insulation of more than 5 dB, fully demonstrating that the composite curing process of this application is a key supporting technical feature for ensuring high sound insulation performance.

[0051] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A multi-layer laminated soundproof glass, characterized in that, It is made of multiple layers of glass sheets bonded together, with the thickness of the sheets gradually increasing from the outside to the inside.

2. The multi-layer laminated soundproof glass as described in claim 1, characterized in that, The glass material is such as float glass, tempered glass, semi-tempered glass, or ultra-clear glass; the thickness of the glass sheet is 4~12mm, wherein the thickness of the inner glass is at least 1mm greater than that of the adjacent outer glass; preferably, the thickness difference is 2mm or more.

3. The multi-layer laminated soundproof glass as described in claim 1, characterized in that, The soundproof glass is made of three layers of glass sheets bonded together, with thicknesses of 5mm+6mm+5mm, or 5mm+7mm+5mm, or 6mm+7mm+6mm, or 6mm+8mm+6mm, or 4mm+5mm+4mm respectively. Alternatively, the soundproof glass is made of four layers of glass sheets bonded together, with thicknesses of 5mm+6mm+8mm+5mm, or 5mm+6mm+7mm+5mm, or 6mm+8mm+10mm+6mm, or 5mm+6mm+7mm+5mm, or 5mm+7mm+9mm+5mm.

4. The multi-layer laminated soundproof glass as described in claim 1, characterized in that, The raw materials for preparing the soundproof glass also include a soundproof film, which is placed between the original glass sheets. The soundproof film gradually increases in damping from the outside to the inside. Feasible soundproof film materials include, but are not limited to, polyvinyl butyral film, SGP ionic interlayer film, modified butyl rubber soundproof film, nitrile rubber soundproof film, and thermoplastic elastomer TPE / TPV soundproof film.

5. The multi-layer laminated soundproof glass as described in claim 4, characterized in that, When the glass has 3 layers, 2 layers of sound insulation film are selected: the first layer is a transparent modified butyl rubber sound insulation film with a thickness of 0.8–1.2 mm and a modulus of 10–15 MPa; the second layer is an SGP ionomer interlayer film with a thickness of 0.76 mm and a modulus of 80–120 MPa. When the glass has 4 layers, 3 layers of sound insulation film are selected: the first layer is a soft PVB sound insulation film with a thickness of 0.38 mm and a modulus of 20–30 MPa; the second layer is a transparent modified butyl rubber sound insulation film with a thickness of 0.8–1.2 mm and a modulus of 10–15 MPa; and the third layer is an SGP ionomer interlayer film with a thickness of 0.76 mm and a modulus of 80–120 MPa.

6. The lamination process of the multilayer laminated soundproof glass according to any one of claims 1-5, characterized in that, Includes the following steps: Select a sound-insulating film based on the chosen glass sheet, assemble the sheets, transfer them to a vacuum bag and preheat for initial bonding to obtain a pre-assembled sheet; transfer the pre-assembled sheet into an autoclave and cure it through segmented temperature and pressure control, then slowly cool it through step-down cooling, and seal the edges to obtain the final product; The segmented temperature and pressure control method is as follows: The first stage involves controlling the heating rate inside the autoclave at 1–2℃ / min, raising the temperature to 70–85℃, and simultaneously introducing compressed air into the autoclave to raise the pressure inside to 0.4–0.6MPa. This temperature and pressure are maintained for 10–15 minutes. The purpose of this stage is to slowly soften each layer of sound insulation film, fully wet the glass surface, and allow any remaining microbubbles between the layers to slowly migrate to the glass edge for easy removal. The second stage: medium-temperature and medium-pressure fusion stage: control the heating rate in the autoclave at 2–3℃ / min, raise the temperature to 95–110℃, and at the same time raise the pressure in the autoclave to 0.8–1.1MPa, and maintain this temperature and pressure for 15–20min; the purpose of this stage is to fuse the multiple layers of sound insulation films with different moduli together, eliminate the gaps between the layers, achieve complete bonding between each layer of film and glass, and further remove residual air bubbles; The third stage: High temperature and high pressure shaping stage: The heating rate inside the autoclave is controlled at 1–2℃ / min, raising the temperature to 125–140℃, while the pressure inside the autoclave is raised to 1.2–1.5MPa, and this temperature and pressure are maintained for 30–45min; the purpose of this stage is to fully cross-link and cure the sound insulation film, ensuring the bonding strength between each layer of glass and the film, while improving the structural stability and safety performance of the laminated glass.

7. The lamination process of the multi-layer laminated soundproof glass as described in claim 6, characterized in that, The stepped cooling method is as follows: First stage: Reduce the temperature inside the autoclave from 140℃ to 110℃, controlling the cooling rate at 2–3℃ / min, while keeping the pressure inside the autoclave constant throughout the process; Second stage: Reduce the temperature inside the autoclave from 110℃ to 70℃, control the cooling rate at 1–2℃ / min, and keep the pressure inside the autoclave constant throughout the process; Third stage: After the temperature inside the autoclave drops below 70°C, stop the pressure holding and allow it to cool naturally to room temperature.

8. The lamination process of the multi-layer laminated soundproof glass as described in claim 6, characterized in that, The specific steps of the lamination process are as follows: S1. Select a clean and dry glass sheet for plasma activation treatment, select a sound-insulating film and cut it according to the size of the sheet; the parameters of the plasma activation are as follows: process for 30–60 seconds at a power of 80–120W; S2. In a clean room, the original glass sheet and the sound insulation film are laid out in sequence and then assembled. The glass sheet is then placed in a vacuum bag and vacuumed at -0.090 to -0.095 MPa. The whole bag is preheated by holding the pressure at 50–65℃ for 15–25 minutes to obtain the pre-assembled sheet. S3. Transfer the pre-assembled sheet obtained in S2 into an autoclave and cure it in stages with controlled temperature and pressure as described above. During the curing process, control the temperature fluctuation in the autoclave to ≤±1℃ and the pressure fluctuation to ≤±0.05MPa. Then, slowly cool it through the above-mentioned step cooling method to obtain the assembled sheet product. S4. Clean the edges of the assembled product, and then seal the edges with butyl sealant and structural adhesive. The thickness of the butyl sealant is 1.5–2.0 mm, the thickness of the structural adhesive is 2.0–2.5 mm, and the sealing width is 5–8 mm.

9. The lamination process of the multi-layer laminated soundproof glass as described in claim 8, characterized in that, In S1, the purpose of plasma activation is to enhance the activity of the glass surface and strengthen the adhesion to the sound insulation film. After pretreatment, the glass is placed in a Class 1000 cleanroom for later use to avoid secondary contamination.

10. The lamination process of the multi-layer laminated soundproof glass as described in claim 8, characterized in that, In S2, the lamination process is as follows: The pre-treated glass sheet is placed on a positioning fixture, and a first layer of sound-insulating film is laid. The film is then flattened using a vacuum leveling device to ensure complete adhesion between the film and the surface of the glass sheet, without wrinkles or bubbles. A second glass sheet is then placed, and its precise positioning is achieved using a CCD vision alignment system, ensuring that the misalignment between the second and first glass sheets is ≤0.2mm. A second layer of sound-insulating film is laid on the upper surface of the second glass sheet, and it is again flattened using a vacuum leveling device. This alignment and leveling process is repeated to form a multi-layered laminated pre-laminated semi-finished product. The pre-laminated semi-finished product is then placed into a vacuum bag, sealed, and vacuum-treated.

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