Multilayer Glass Enamel Firing Separation Layer
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Solution Overview
Problem
In the production of multilayer glass structures, the crystallizing enamels on the bottom sheet can undesirably adhere to the top sheet during firing, causing damage to either or both sheets, which is a challenge in forming laminated glass windshields.
Innovation Solution
The introduction of a separation layer, such as a black pigment, refractory material, or oxidizer layer between the glass sheets, which improves separation and prevents enamel sticking by facilitating the burn-out of the organic binder and promoting the sintering of the enamel to one glass sheet while maintaining separation from the other.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a crystallizing enamel composition is applied to the bottom glass sheet and then a top glass sheet is stacked on top, then the enamel provides decorative coloring and UV protection, but the enamel undesirably adheres to the top sheet during firing causing damage to one or both sheets
Solution Approach 1:
A separation layer comprising a separation agent is introduced between the enamel composition layer on the bottom glass sheet and the top glass sheet. The separation agent prevents undesirable adhesion during firing while allowing the enamel to properly adhere to the bottom sheet, thus mediating between the need for enamel bonding and the need to prevent sticking to the top sheet.
Solution Approach 2:
The interface region between the enamel and top glass sheet is segmented by introducing a distinct separation layer. This layer is positioned only at the interface where sticking occurs, allowing the enamel to remain continuous and adherent to the bottom sheet while being separated from the top sheet only where necessary.
2Reliability
If multiple heating steps are used to fire the enamel and fuse the glass layers, then the enamel properly bonds to the substrate and the layers fuse together, but the process becomes complex and time-consuming
Solution Approach 1:
The separation layer is designed to perform multiple functions simultaneously: it prevents enamel sticking to the top sheet, allows proper enamel bonding to the bottom sheet, and facilitates layer fusion during the same firing cycle. This merging of functions into a single layer reduces the need for multiple separate heating steps.
Solution Approach 2:
The separation agent in the separation layer is selected based on its thermal behavior characteristics - it remains stable at enamel firing temperatures but decomposes or becomes inactive at the higher temperatures required for glass layer fusion. This parameter-based differentiation allows a single heating cycle to achieve both enamel bonding and layer fusion without sticking.
3Manufacturing precision
If the enamel composition is fired at high temperature to achieve proper sintering and bonding, then the enamel fuses to the glass substrate, but the organic binder molecules do not completely burn off causing defects
Solution Approach 1:
The separation layer is applied before firing and remains in place during the enamel sintering process. It prevents organic binder residues from migrating or causing defects during the high-temperature sintering, effectively protecting the enamel bonding process while allowing complete burn-off of organics.
Solution Approach 2:
The separation layer acts as an intermediary barrier that manages the interaction between the organic binder decomposition products and the enamel matrix during heating. It allows the organic binder to decompose completely while preventing residue formation that would compromise enamel quality.
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
This method effectively prevents enamel transfer and sticking between glass sheets, ensuring proper separation and fusion of the glass layers, thereby enhancing the structural integrity and optical quality of the laminated glass windshields.
Implementation Method 1
a refractory material separation layer comprising refractory material in an amount sufficient to improve separation of the first and second glass sheets
Implementation Method 2
an oxidizer separation layer comprising an oxidizer in an amount sufficient to improve separation of the first and second glass sheets
Implementation Method 3
firing the glass sheets to sinter the first enamel composition to the first glass sheet
Data Source
AI summary
Methods of making multilayer glass structure are described. The method involves providing first and second glass sheets, and a first enamel composition layer and at least one separation layer between the first and second glass sheets, and firing the glass sheets to sinter the first enamel composition to the first glass sheet. The separation layer is a black pigment separation layer, a refractory material separation layer, or an oxidizer separation layer. The separation layer can improve separation of the first and second glass sheets after the firing.