Multilayer Glass Laminate Edge Defect Reduction
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Solution Overview
Problem
The manufacturing of multilayer glass laminate panels often results in edge defects such as bubbles, which affect optical quality and edge integrity, due to residual air trapped between the substrates and interlayer, and are exacerbated by high temperatures and pressures during the autoclaving process.
Innovation Solution
Optimizing autoclave conditions by reducing temperature and pressure, and adjusting hold time to between 10 minutes to 60 minutes, with a temperature range of 110°C to 155°C and pressure range of 2 to 9 bars, to minimize air dissolution and diffusion in the interlayer, thereby reducing edge bubbles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high temperature and pressure are applied during autoclaving to ensure complete bonding of the interlayer to the substrates, then bonding strength is improved, but edge bubbles are formed due to air dissolution and expansion
Solution Approach 1:
The patent applies preliminary vacuum de-airing before autoclaving to remove trapped air from the laminate assembly. This preliminary action prevents air from being dissolved into the interlayer during subsequent autoclaving, thereby preventing edge bubble formation while allowing high temperature and pressure bonding to proceed
Solution Approach 2:
The patent uses a rapid vacuum de-airing process that completes air removal in a short time frame before autoclaving begins. This rushing through the de-airing step ensures trapped air is eliminated quickly, preventing it from causing edge bubbles during the bonding process
2Duration of action of stationary object
If extended hold time is used during autoclaving to ensure complete bonding, then bonding quality is improved, but air has more time to dissolve and diffuse in the interlayer, increasing edge bubbles
Solution Approach 1:
By performing vacuum de-airing before autoclving, the patent removes the source of air that would otherwise dissolve and diffuse during the hold time. This preliminary air removal allows extended hold times to be used for complete bonding without the risk of air-related edge bubbles
3Object-generated harmful factors
If vacuum de-airing is applied before autoclving to remove trapped air, then edge bubbles are reduced, but residual air remains that can still dissolve during autoclving
Solution Approach 1:
The patent employs a rapid and thorough vacuum de-airing process that efficiently removes the majority of trapped air before autoclving begins. This rushing through the de-airing step maximizes air removal effectiveness, leaving minimal residual air that could dissolve during autoclving
Solution Approach 2:
The patent optimizes vacuum de-airing parameters including vacuum level, duration, and temperature to maximize air removal efficiency. By adjusting these parameters, the process achieves more complete air evacuation, reducing the amount of residual air available to dissolve during subsequent autoclving
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 optimized process significantly reduces edge defects, enhancing the optical quality and edge integrity of multilayer glass laminate panels without compromising their mechanical and acoustic properties.
Implementation Method 1
autoclaving the produced laminate by applying heat and pressure to the laminate for a hold time
Implementation Method 2
minimize air dissolution and diffusion in the interlayer
Implementation Method 3
minimize air dissolution and diffusion in the interlayer
Data Source
Figure 1~2
Figure 3
AI summary
A process for producing a multilayer glass laminate panel having two glass sheets with a polyvinyl butyral) interlayer sandwiched therebetween, the process comprising the steps of: providing two glass sheets; providing a polyvinyl butyral) interlayer, and inserting the interlayer between the two glass sheets to produce a laminate; removing air from the produced laminate; applying heat and pressure to the laminate for a hold time, wherein the laminate is free of bubbles at the edges of the laminate. The multilayer glass laminate panel has improved optical properties, and specifically reduced levels of edge defects, such as edge bubbles in the laminate.