Fire-Resistant Composite Glass Primer Layer Design
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Solution Overview
Problem
Existing fire-resistant composite glass manufacturing methods are labor-intensive and time-consuming, requiring autoclaving and complex processes for achieving both fire-resistant and attack-resistant characteristics.
Innovation Solution
A fire-resistant composite glass design featuring a solid polycarbonate attack-resistant layer and a foaming/swelling fire-resistant intermediate layer, with a primer layer that reduces adhesion at high temperatures to prevent detachment, allowing for simpler manufacturing without autoclaving, using materials like polycarbonate, alkali silicate, and hydrogel layers, and employing a polyethylene wax primer and butyl polymer spacers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If autoclaving method is used to manufacture fire-resistant composite glass, then fire-resistant characteristics and attack-resistant characteristics are achieved, but manufacturing complexity and time consumption increase significantly
Solution Approach 1:
The patent extracts and eliminates the autoclaving process from the manufacturing method. The intermediate layer is designed to foam automatically under fire conditions without requiring pre-autoclaving, thereby removing the complex autoclaving equipment and process steps while maintaining fire-resistant performance.
Solution Approach 2:
The primer layer is applied in advance to the glass pane before assembling the composite structure. This preliminary action ensures proper adhesion and positioning of the intermediate layer, eliminating the need for subsequent autoclaving to secure the layers together.
2Reliability
If autoclaving method is used to manufacture fire-resistant composite glass, then fire-resistant characteristics and attack-resistant characteristics are achieved, but manufacturing time increases significantly
Solution Approach 1:
The autoclaving step is completely removed from the manufacturing process. The composite glass can be assembled and used directly without the time-consuming autoclaving cycle, significantly reducing manufacturing time while maintaining attack-resistant properties through the polycarbonate layer.
Solution Approach 2:
The intermediate layer is designed to perform its fire-resistant function automatically when exposed to fire conditions, without requiring prior autoclaving treatment. The layer self-activates under heat, foaming to provide insulation and maintaining the integrity of the composite structure.
3Reliability
If primer layer adhesion is strong at high temperatures, then glass and intermediate layer remain bonded during fire, but detachment occurs under normal thermal expansion conditions
Solution Approach 1:
The primer layer's adhesion properties are designed to change with temperature. At normal temperatures, the primer provides sufficient adhesion to bond the glass and intermediate layer. At high fire temperatures, the primer's adhesion strength increases significantly, preventing detachment despite thermal expansion and mechanical stresses.
Solution Approach 2:
The primer layer exhibits dynamic adhesion characteristics that adapt to temperature conditions. The adhesion strength is not static but varies with temperature, being adequate at room temperature and dramatically increasing at fire temperatures to prevent detachment of the intermediate layer.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the production of fire-resistant composite glass with improved manufacturability and performance, maintaining cohesion during high-temperature conditions while preventing gaps in the fire-resistant layer, thus ensuring effective fire and impact resistance without the need for autoclaving.
Implementation Method 1
gas arises or the gas substance quantity is increased, in the intermediate space between the carrier elements, given the effect of heat under fire safety test conditions (for example, with temperatures acting upon the composite glass with a thermal loading as a function of time according to ISO 834-1), due to a physical phase conversion (evaporation of water or another solvent, for example in small bubbles with foaming materials, liquefaction of a solid substance)
Implementation Method 2
due to a chemical reaction, for example a thermal decomposition (pyrolysis)
Implementation Method 3
The primer layer can be designed, for example, such that its adhesion onto the fire-resistant intermediate layer significantly reduces at temperatures close to the boiling point of water, i.e. at temperatures of above approx, 80° or above approx. 90°
Data Source
AI summary
A flame-retardant composite glass including a plurality of glass panes and a flame-retardant intermediate layer that is arranged between two first glass panes and includes a flame-retardant material that foams or swells up in the event of a fire, as well as an attack-resistant layer having a transparent plastic that is solid at room temperature. The flame-retardant composite glass has, between the first glass panes, an edge compound extending along and around the edges such that a chamber filled with said flame-retardant material is defined by the first glass panes and the edge compound. Between at least one of the first glass panes and the flame-retardant material, a primer layer is arranged that includes a material whose adhesion to the flame-retardant intermediate layer and/or to the glass pane becomes weaker in flame-retardant test conditions than it is in room temperature conditions.