Laminated Glass Edge Gap Reduction via Ceramic Paste Shrinkage Compensation
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Solution Overview
Problem
Laminated glass manufacturing for vehicles faces challenges in preventing edge gaps between glass sheets of different types and thicknesses due to firing shrinkage of ceramic pastes, which affects the bend degree and bonding process.
Innovation Solution
The method involves applying different amounts or compositions of ceramic pastes to glass sheets to minimize firing shrinkage differences, allowing for identical bending and reducing edge gaps by adjusting the ceramic paste application on each sheet, thereby ensuring reliable bonding without excessive pressure or special interlayer films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the same amount and composition of ceramic paste is applied to glass sheets of different types and thicknesses, then the manufacturing process is simple, but edge gaps are generated due to differences in firing shrinkage
Solution Approach 1:
The patent applies different amounts and/or compositions of ceramic paste to different glass sheets based on their specific properties (type, thickness). This local customization of paste application compensates for differences in firing shrinkage rates, ensuring that glass sheets with different characteristics achieve consistent bend degrees after firing, thereby preventing edge gaps without requiring complex overall process changes
Solution Approach 2:
The patent modifies the parameters of ceramic paste application (amount per unit area, composition) according to the specific glass sheet properties. By adjusting these parameters, the firing shrinkage of each glass sheet is controlled to achieve uniform bend degrees, resolving the edge gap problem while maintaining manufacturing feasibility
2Reliability
If glass sheets of different types and thicknesses are used to reduce weight and solar transmittance, then vehicle safety and comfort are improved, but bend degree differences cause edge gaps during lamination
Solution Approach 1:
The patent enables the use of different glass sheet types and thicknesses (clear glass for strength, tinted glass for solar shielding) by applying customized ceramic paste to each. This local adjustment of paste characteristics compensates for their different thermal and mechanical properties during firing, ensuring consistent bend degrees and preventing edge gaps while maintaining the functional benefits of diverse glass selection
Solution Approach 2:
The patent adjusts ceramic paste parameters (amount, composition) to compensate for differences in glass sheet properties. This allows the use of functionally different glass sheets (different types, thicknesses) while controlling their firing behavior to achieve uniform bend degrees, thus resolving the manufacturing precision issue without sacrificing the reliability and performance benefits
3Strength
If excessive pressure is applied during bonding to close edge gaps, then bonding strength is improved, but the complexity and risk of the manufacturing process increase
Solution Approach 1:
The patent performs preliminary adjustment of ceramic paste characteristics before the bonding process. By pre-compensating for firing shrinkage differences through customized paste application, the glass sheets are prepared in advance to achieve consistent bend degrees, thereby eliminating the need for excessive pressure during bonding and simplifying the overall manufacturing process
Solution Approach 2:
The patent applies preliminary counter-measures by adjusting ceramic paste parameters to prevent the formation of excessive edge gaps before bonding occurs. This preemptive adjustment of paste characteristics counteracts the potential for bend degree differences, thereby eliminating the need for high-pressure bonding while maintaining bonding strength
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 effectively reduces edge gaps and ensures consistent bend degrees between glass sheets, enhancing the bonding process and shielding properties of the laminated glass, allowing for reliable assembly without excessive pressure or specialized interlayer films.
Implementation Method 1
the outer sheet 90 and inner sheet 91 may not coincide with each other in the bend degree due to firing shrinkage of the ceramic pastes 920 and 930
Implementation Method 2
firing the ceramic paste that has been printed
Data Source
AI summary
A ceramic paste is applied to a first glass sheet 11, and a ceramic paste is applied to a second glass sheet 13 with a lower solar absorptivity than that of the first glass sheet 11. In this case, the amount per unit area of the ceramic paste to be applied to the first glass sheet 11 is allowed to be smaller than that of the ceramic paste to be applied to the second glass sheet 13. Alternatively, a first ceramic paste and a second ceramic paste are allowed to have different compositions from each other. The first glass sheet 11 and the second glass sheet 13 are bent so that the surfaces onto which the ceramic pastes have been applied are shaped as concave surfaces. The applied ceramic paste is fired using the heating used for bending. Thus maskings 12 and 14 are formed. The first glass sheet 11 and the second glass sheet 13 are bonded to each other, with a resin interlayer film 15 being interposed therebetween.