Laminated Glass Pressure-Sensitive Adhesive Single-Stage Lamination
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Solution Overview
Problem
The existing manufacturing processes for laminated glazing with heat-sensitive functional layers require multiple lamination stages, which are time-consuming, energy-intensive, and difficult to integrate with polyvinyl butyral (PVB) layers due to high autoclaving temperatures, causing damage to the functional layers.
Innovation Solution
A laminated glazing structure comprising a first glass sheet, a thermoplastic polymer interlayer, an optional solar-protection sheet, a second glass sheet, and a pressure-sensitive adhesive layer in contact with a heat-sensitive functional sheet, allowing for a single hot lamination stage using a polymeric interlayer, which maintains the integrity of both impact resistance and heat sensitivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple lamination stages are used to manufacture laminated glazing with heat-sensitive functional layers, then the functionality of heat-sensitive layers is preserved, but the manufacturing process becomes time-consuming and energy-intensive
Solution Approach 1:
The patent changes the temperature parameter of the lamination process by using a two-stage approach: first a low-temperature stage (below 100°C) to bond the heat-sensitive functional layer without damage, then a high-temperature stage (120-145°C) to properly cure the PVB interlayer. This parameter sequencing resolves the contradiction by preserving functionality while achieving complete lamination.
Solution Approach 2:
The patent applies preliminary action by first bonding the heat-sensitive functional layer to the glass substrate at low temperature before introducing the PVB interlayer and performing high-temperature autoclaving. This preliminary low-temperature bonding step protects the functional layer from subsequent high-temperature damage while still allowing complete lamination to occur.
2Reliability
If multiple lamination stages are used to manufacture laminated glazing with heat-sensitive functional layers, then the functionality of heat-sensitive layers is preserved, but energy consumption increases
Solution Approach 1:
The patent optimizes energy usage by carefully controlling temperature parameters across two stages. The first stage uses minimal energy at low temperature to protect the functional layer, while the second stage concentrates energy input only when the functional layer is already protected, achieving complete PVB curing with minimal wasted energy.
Solution Approach 2:
The patent maintains continuous useful action by seamlessly transitioning from low-temperature bonding to high-temperature autoclaving without removing or handling the intermediate assembly. This continuous process minimizes energy losses associated with cooling down and reheating, reducing overall energy consumption while preserving functional layer integrity.
3Strength
If high autoclaving temperature is used for PVB lamination, then strong bonding between glass and interlayer is achieved, but heat-sensitive functional layers are damaged
Solution Approach 1:
The patent applies preliminary low-temperature bonding to attach the heat-sensitive functional layer to the glass substrate before introducing the PVB interlayer. This preliminary action creates a protected configuration where the functional layer is already bonded and shielded during the subsequent high-temperature autoclaving process, allowing strong PVB bonding without functional layer damage.
Solution Approach 2:
The patent segments the lamination process into two distinct temperature stages: a first low-temperature stage for bonding heat-sensitive layers, and a second high-temperature stage for PVB curing. This temporal and thermal segmentation allows each material to be processed at its optimal temperature, achieving both functional layer preservation and strong interlayer bonding.
4Productivity
If a single hot lamination stage is used, then manufacturing efficiency is improved, but heat-sensitive functional layers are damaged
Solution Approach 1:
The patent segments the lamination process into two continuous stages within a single manufacturing run: low-temperature bonding followed by high-temperature autoclaving. This segmentation within a continuous process maintains high productivity while protecting functional layers, as the transition between stages occurs in-situ without removing or handling the intermediate assembly.
Solution Approach 2:
The patent maintains continuous manufacturing action throughout the two-stage process, with the autoclave continuously heating from low to high temperature without interrupting the lamination sequence. This continuous useful action achieves both functional layer protection and complete PVB curing in a single uninterrupted manufacturing cycle, preserving productivity.
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 enables the production of impact-resistant laminated glazing with heat-sensitive active films in a single stage, reducing energy consumption and handling operations while preserving the functionality of the heat-sensitive layers.
Implementation Method 1
a layer of pressure-sensitive adhesive in direct contact with a heat-sensitive functional sheet
Implementation Method 2
PVB has the advantage of exhibiting a good adhesion to glass and a high degree of elongation before tearing... the PVB interlayer keeps the pieces of glass in place, which reduces the risk of being cut by glass splinters and makes it possible to retain the leaktightness of the glazing. Finally, the residual energy of the body is absorbed by this interlayer.
Data Source
AI summary
A laminated glazing includes a first glass sheet, a first interlayer sheet made of thermoplastic polymer; optionally a solar-protection sheet or functional metal layer having reflective properties in the infrared region and/or in the solar radiation region; a sheet of pressure-sensitive adhesive, in direct contact with a heat-sensitive functional sheet; a second glass sheet; the first glass sheet being in direct contact with the interlayer sheet; the second glass sheet being in direct contact with the sheet of pressure-sensitive adhesive; the sheet of pressure-sensitive adhesive and the second glass sheet are in direct contact at the external face of the latter.