Glass Sheet Composite Bubble-Free Manufacturing
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Solution Overview
Problem
The existing glass sheet composites with liquid layers often contain bubbles, which impair appearance, acoustic performance, and make it difficult to maintain consistent acoustic reproduction across temperature changes.
Innovation Solution
A manufacturing method involving applying a liquid agent and sealant to one glass sheet, bonding it with another sheet, and subjecting the laminate to reduced pressure in a decompression chamber with controlled pressure and viscosity coefficients to prevent bubble formation, ensuring the intermediate layer remains bubble-free.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum lamination method is used to apply liquid agent and sealant under reduced pressure, then bubble removal is improved, but complete bubble elimination is difficult to achieve
Solution Approach 1:
The patent applies the liquid agent and sealant to the glass sheet at atmospheric pressure before bonding, allowing proper coating and positioning. Only after the laminate is formed does it subject the entire structure to reduced pressure to remove bubbles. This preliminary action at atmospheric pressure ensures complete coverage while the subsequent vacuum phase eliminates bubbles, achieving both good adhesion and bubble-free intermediate layer.
Solution Approach 2:
The patent maintains continuous bonding pressure during the entire process. The liquid agent and sealant are applied under atmospheric pressure with continuous contact, then the laminate is bonded continuously, and finally reduced pressure is applied continuously to remove bubbles. This continuous action ensures complete bubble elimination while maintaining strong adhesion between sheets.
2Manufacturing precision
If reduced pressure is applied to remove bubbles from intermediate layer, then appearance is improved, but bonding strength may be compromised
Solution Approach 1:
The patent first applies the liquid agent and sealant at atmospheric pressure to ensure proper coating thickness and distribution. The bonding process is completed at atmospheric pressure to establish strong initial adhesion. Only after bonding is established does the patent apply reduced pressure to remove bubbles. This preliminary bonding at atmospheric pressure ensures strength is not compromised during the bubble removal phase.
Solution Approach 2:
The patent carefully controls the reduced pressure parameter, reducing pressure to 100 Pa or less but maintaining it for a controlled duration (1-180 minutes). The pressure reduction is gradual and controlled, not abrupt. This parameter control allows bubble removal while preventing excessive pressure differential that could compromise bonding strength or cause delamination.
3Reliability
If viscosity of sealant is increased to prevent bubble formation, then bubble resistance is improved, but ease of application deteriorates
Solution Approach 1:
The patent specifies a viscosity coefficient of 1×10−1 Pa·s or more for the sealant, which provides sufficient bubble resistance while remaining workable. This viscosity parameter is optimized to prevent bubbles from forming during application and bonding, yet the sealant remains fluid enough for practical application by coating methods. The viscosity is not excessively high, maintaining ease of manufacture.
Solution Approach 2:
The sealant is applied at atmospheric pressure in a preliminary coating step, allowing proper spreading and positioning before bonding. The application is performed while the material is still in its original state, not after pressure changes. This preliminary application at atmospheric pressure ensures ease of coating while the subsequent reduced pressure phase prevents bubble formation, combining both benefits.
4Manufacturing precision
If liquid agent viscosity is decreased to improve coating, then coating quality is improved, but bubble stability increases
Solution Approach 1:
The patent specifies a viscosity coefficient of 1×103 Pa·s or less for the liquid agent, which allows for good coating quality and flow during application. However, this viscosity is not excessively low, as very low viscosity would allow bubbles to remain stable. The patent then applies reduced pressure (100 Pa or less) to destabilize and remove bubbles. This combination of moderate viscosity control and pressure reduction achieves both good coating quality and bubble elimination.
Solution Approach 2:
The patent applies the liquid agent continuously at atmospheric pressure to ensure uniform coating, then immediately subjects the laminate to continuous reduced pressure to remove bubbles. This continuous action from coating through bonding to vacuum treatment ensures that any bubbles formed during the low-viscosity coating phase are continuously removed, preventing stable bubble formation while maintaining coating 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
The method produces glass sheet composites with excellent appearance and acoustic performance, maintaining consistent sound reproduction even at varying temperatures without bubble-induced damping effects.
Implementation Method 1
subjecting the laminate to reduced pressure
Data Source
AI summary
The present invention relates to a method for manufacturing a glass sheet composite including two or more sheets and an intermediate layer between at least a pair of sheets of the sheets, the pair of the sheets consisting of a sheet 1A and a sheet 1B, at least one of the sheet 1A and the sheet 1B being a glass sheet, and the method including: applying a liquid agent for the intermediate layer and a sealant to at least a part of a main surface of the sheet 1A; bonding the sheet 1B to the main surface of the sheet 1A to which the liquid agent for the intermediate layer and the sealant are applied to obtain a laminate; and subjecting the laminate to reduced pressure.