Laminated Glazing Process for Asymmetric Glass Alignment
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Solution Overview
Problem
The automotive industry faces challenges in producing lightweight laminated glazings for vehicle side windows that meet safety and quality standards, as existing methods struggle to shape ultra-thin glass plies and achieve optimal optical properties while minimizing weight.
Innovation Solution
A process involving a first glass sheet with a specific thickness and composition, a second flat glass sheet with a different thickness and composition, and an interlayer structure, where the second glass sheet is molded to align with the first sheet's shape during lamination at controlled temperature and pressure, using a support sheet with higher rigidity than the adhesive interlayer to ensure bonding and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If ultra-thin glass sheets are used to reduce weight, then the weight of the laminated glazing is reduced, but the difficulty of shaping and aligning the glass sheets increases
Solution Approach 1:
A mould shaped substantially the same as the first glass sheet is introduced as an intermediary tool during lamination. The mould receives the second glass sheet and imparts the correct shape and alignment, enabling precise positioning of ultra-thin glass sheets that would otherwise be difficult to handle and align manually
Solution Approach 2:
The mould is prepared in advance with the target shape corresponding to the first glass sheet. By having the mould ready before lamination, the second glass sheet can be directly shaped and aligned during the lamination process without requiring complex post-processing or adjustment operations
2Weight of moving object
If different thickness glass sheets are used to reduce weight, then the weight of the laminated glazing is reduced, but the complexity of the lamination process increases
Solution Approach 1:
The mould acts as a mediator that accommodates glass sheets of different thicknesses. By receiving the second glass sheet and shaping it against the mould, the process simplifies the handling of asymmetric thickness configurations, allowing the lamination of differently thick glass sheets without requiring complex specialized equipment
Solution Approach 2:
The process accommodates variations in glass sheet thickness parameters by using the mould to define the final shape. The mould compensates for thickness differences during lamination, enabling the use of asymmetric glass configurations (such as ultra-thin second glass sheet) without increasing process complexity
3Strength
If glass sheets are heated to bonding temperature, then the bonding strength between layers is improved, but the risk of deformation increases
Solution Approach 1:
The mould is prepared in advance with the exact target shape. During heating and lamination, the second glass sheet is pressed against the pre-formed mould, which guides it into the correct shape before the adhesive sets. This preliminary preparation of the mould shape ensures that even at elevated temperatures, the glass maintains the desired form
Solution Approach 2:
The mould serves as a thermal and mechanical intermediary during the heating process. It provides a stable reference surface that prevents deformation of the glass sheets while they are being bonded, absorbing and distributing thermal stresses uniformly to maintain shape integrity during the heating and cooling cycles
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 process enables the production of lightweight laminated glazings with improved optical properties and structural integrity, meeting commercial and safety standards by effectively aligning and bonding the glass sheets, resulting in a laminated glazing that is both strong and efficient.
Implementation Method 1
laminating together the first and second glass sheets and the interlayer at a temperature and pressure sufficient to adhere the interlayer material to the glass sheets
Data Source
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AI summary
The present invention relates to a laminated glazing, a process for preparing a laminated glazing and the use of same in a vehicle wherein the process comprises the steps of: providing a first glass sheet with a first composition formed into a desired shape with a first thickness and with a first composition; providing a second substantially flat glass sheet with a second composition and a second thickness, and wherein the thickness of the first sheet is different to the thickness of the second glass sheet; providing an interlayer structure located between the first and second glass sheet; and providing a mould which is shaped substantially the same as the first glass sheet against the second glass sheet; and laminating together the first and second glass sheets and the interlayer at a temperature and pressure sufficient to adhere the interlayer material to the glass sheets, such that after lamination, the shape of the second glass sheet is sufficiently aligned with the shape of the first glass sheet.