Glass Sheet Lamination Heating Control for Consistent Bonding
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Solution Overview
Problem
Variation in the initial temperature of glass sheets during the lamination process leads to inconsistent lamination quality and increased production costs, as overly high or low temperatures can result in air bubbles and inadequate bonding between glass and plastic layers.
Innovation Solution
A method and apparatus where the temperature of at least one glass sheet is measured before entering the lamination furnace, and the heating effect is adjusted by a computer-controlled system to ensure consistent target temperatures, adjusting the duration of heating and the conveying speed of the roller track to compensate for temperature variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the glass sheets are heated in a lamination furnace to a fixed target temperature, then the bonding temperature is sufficient for strong adhesion, but temperature variations in the input glass sheets cause inconsistent lamination quality
Solution Approach 1:
The patent measures the temperature of glass sheets before they enter the lamination furnace and uses this information to pre-adjust the heating parameters. This preliminary measurement and adjustment action ensures that despite variations in input temperature, the glass sheets reach the correct bonding temperature for consistent lamination quality.
Solution Approach 2:
The patent implements a feedback control system where temperature measurements of the glass sheets are continuously monitored and used to adjust the heating effect of the lamination furnace. The computer controls the heating duration and intensity based on real-time temperature data, ensuring consistent output temperature and lamination quality despite input variations.
2Temperature
If the heating effect of the lamination furnace is increased to compensate for low input temperatures, then bonding temperature is achieved, but energy consumption increases
Solution Approach 1:
The patent dynamically adjusts the heating parameters of the lamination furnace based on the measured temperature of each glass sheet. Instead of using a fixed heating regime, the system modifies heating duration and intensity in real-time according to actual temperature conditions, optimizing energy usage while ensuring target temperature is always reached.
Solution Approach 2:
The patent changes the heating parameters (duration, intensity) of the lamination furnace based on the measured temperature of the glass sheets. The computer adjusts these parameters to match the actual thermal state of each sheet, ensuring efficient energy use while achieving consistent bonding temperatures.
3Manufacturing precision
If the lamination furnace heating duration is extended to ensure adequate heating, then bonding quality improves, but production speed decreases
Solution Approach 1:
The patent measures the temperature of glass sheets before heating and uses this information to determine the optimal heating duration. This preliminary temperature assessment allows the system to set the minimum necessary heating time for each sheet, avoiding unnecessary extended heating while ensuring adequate bonding quality is achieved.
Solution Approach 2:
The patent dynamically adjusts the heating duration in the lamination furnace based on real-time temperature measurements of each glass sheet. The computer controls the heating process to last only as long as necessary for each specific sheet, optimizing the balance between bonding quality and production throughput.
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 approach significantly reduces quality variations and associated costs by ensuring consistent lamination quality, even with temperature variations, by optimizing the heating process based on real-time temperature measurements.
Implementation Method 1
the sandwich structure sheet is heated in a lamination furnace
Implementation Method 2
the temperature of at least one glass sheet comprised in the sandwich structure sheet is measured before the sandwich structure sheet is conveyed into the lamination furnace
Implementation Method 3
the heating effect of the lamination furnace on the sandwich structure sheet is reduced in accordance with the computer calculation if the measured temperature is higher than the default value of the temperature
Data Source
AI summary
By means of a method and an apparatus for laminating glass sheets, the effect of the variation of the initial temperature of the glass on the success of the lamination furnace treatment and the variation of the quality of the laminated glass can be eliminated, thus reducing quality costs. In the method, a sandwich structure sheet including glass and laminating film layers is heated in a lamination furnace, after which the heated sandwich structure sheet is conveyed between a pair of press rolls, and before the lamination furnace is measured the temperature of at least one glass sheet comprised in the sandwich structure sheet, and on the basis of that data, the heating effect of the lamination furnace on the sandwich structure sheet is changed. The apparatus comprises, upstream of the lamination furnace, a temperature measuring device for measuring the temperature of the glass sheets.