Laminated Window Pane Structure for Hurricane Seal Integrity
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Solution Overview
Problem
Existing hurricane windows require thermal strengthening of both glass sheets to maintain the integrity of the polymer interlayer under impact and pressure cycling, which increases manufacturing costs and can lead to either large fragments or dislodged pieces, compromising the window seal.
Innovation Solution
A laminated pane design with a first sheet of high elastic modulus polymer and a second sheet of low CTE glass, where the second sheet is not thermally strengthened, utilizing a polymer interlayer with varying elastic moduli to absorb stress and maintain the seal without excessive distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If both glass sheets are thermally strengthened, then the polymer interlayer integrity is maintained under impact, but manufacturing costs increase and the glass may break into large fragments or small dislodged pieces
Solution Approach 1:
The glass pane is divided into two functional sheets: a first glass sheet (3-12mm) that provides structural support and is thermally strengthened, and a second thin glass sheet (0.3-1mm) that is not thermally strengthened but compensates for distortion. This segmentation allows each sheet to perform its specific function optimally while reducing overall manufacturing complexity and cost.
Solution Approach 2:
Different thermal strengthening treatments are applied to different glass sheets based on their specific functional requirements. The first glass sheet receives full thermal strengthening for structural integrity, while the second glass sheet remains untreated to provide distortion compensation, creating local quality differences that resolve the contradiction.
2Strength
If thermal strengthening is applied to the second glass sheet, then impact resistance improves, but the glass may break into small pieces that dislodge from the frame, compromising the window seal
Solution Approach 1:
The glass system is segmented into two sheets with different properties: the first sheet handles impact forces while the second untreated thin sheet prevents fragment dislodgement. This segmentation allows the system to maintain seal integrity without requiring the second sheet to be thermally strengthened.
Solution Approach 2:
The polymer interlayer acts as an intermediary between the two glass sheets, bonding them together and preventing fragment dislodgement. The interlayer compensates for the lack of thermal strengthening in the second sheet while maintaining overall impact resistance and seal integrity.
3Shape
If the second glass sheet is made thinner to reduce distortion, then manufacturing flexibility improves, but the sheet becomes more susceptible to damage
Solution Approach 1:
The glass system is divided into two sheets with different thicknesses and functions: the first thicker sheet (3-12mm) provides damage resistance, while the second thinner sheet (0.3-1mm) minimizes distortion. This segmentation allows each sheet to optimize its properties for its specific function.
Solution Approach 2:
The two glass sheets are combined with the polymer interlayer to create a composite structure where the strengths of individual sheets are complementary. The first sheet compensates for the vulnerability of the thin second sheet, while the second sheet compensates for the distortion of the thicker first sheet, achieving overall system optimization.
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 laminated pane design reduces manufacturing costs by eliminating the need for thermal strengthening of the second sheet while maintaining hurricane resistance by preventing damage to the polymer interlayer and ensuring a secure seal under impact and pressure cycling.
Implementation Method 1
utilizing a polymer interlayer with varying elastic moduli to absorb stress and maintain the seal without excessive distortion
Implementation Method 2
a first sheet, of a first transparent or translucent material, the first sheet having a first thickness, and the first transparent or translucent material having a first coefficient of thermal expansion (CTE) measured over a range of from 0 to about 300° C. The laminate pane further includes a second sheet, of a second transparent or translucent material, the second sheet having a second thickness, and the second transparent or translucent material having a second CTE
Data Source
AI summary
A laminated pane for a window includes (1) a first sheet having a first thickness and a first coefficient of thermal expansion (CTE), (2) a second sheet of an inorganic glass having a second thickness and a second CTE, and (3) a polymer interlayer adhered between the first sheet and the second sheet including a layer of a first polymer material having a first elastic modulus and a layer of a second polymer material having a second elastic modulus, wherein the first CTE is greater than the second CTE, the second thickness is in the range of from 1 down to 0.3 mm, and the first elastic modulus is more than 20 times the second elastic modulus.