Layered Glass Embedding Crystal Elements Vacuum Heat Treatment
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Solution Overview
Problem
Conventional methods for creating layered glass with three-dimensional macroscopic elements, such as crystal glass or precious stones, result in defects like air inclusions and tensioning stresses, which deteriorate the decorative, optical, and mechanical characteristics of the product.
Innovation Solution
A method involving a layered structure with an adjustable intermediate layer thickness, formed by superimposing Ethylene-Vinyl-Acetate copolymer layers, and a vacuum heat treatment process to remove air from separation gaps, ensuring proper embedding and positioning of three-dimensional elements without air bubbles or stress induction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If three-dimensional macroscopic elements are embedded in the intermediate layer using conventional methods, then the layered glass gains decorative and optical characteristics, but air inclusions and tensioning stresses are generated that deteriorate the product quality
Solution Approach 1:
The method applies vacuum before and during the heating process to remove air from the separation gaps between the intermediate layer and three-dimensional elements. This preliminary vacuum treatment prevents air inclusions from forming during the embedding process, resolving the contradiction between embedding capability and manufacturing precision.
Solution Approach 2:
The patent creates a vacuum environment (inert atmosphere without air) during the embedding process. By replacing the air-filled environment with a vacuum, the method eliminates air inclusions while maintaining the embedding of three-dimensional elements, thus improving manufacturing precision without sacrificing ease of manufacture.
2Volume of moving object
If the intermediate layer thickness is increased to accommodate larger three-dimensional elements, then the embedding capability is improved, but tensioning stresses increase causing layer breakage
Solution Approach 1:
The method changes the physical parameters of the intermediate layer by heating it to its melting point, transforming it from a rigid state to a viscous fluid state. This parameter change allows the intermediate layer to flow and adapt to the three-dimensional elements without generating tensioning stresses, even when the layer thickness is increased to accommodate larger elements.
Solution Approach 2:
The patent utilizes the phase transition of the intermediate layer from solid to liquid (melting) during the embedding process. This phase transition enables the intermediate layer to conform to the three-dimensional elements without creating stress concentrations, resolving the contradiction between increased thickness for embedding and resistance to tensioning stresses.
3Strength
If heating is applied to activate adhesive properties, then the bonding strength is improved, but air inclusions are generated in the separation gaps
Solution Approach 1:
The patent applies vacuum during the heating process to create an air-free environment. This allows the intermediate layer to be heated and activated for bonding without air inclusions forming in the separation gaps, thus improving adhesive bonding strength without generating harmful air inclusions.
Solution Approach 2:
The method applies vacuum before and during heating to remove air from the separation gaps before the adhesive bonding process occurs. This preliminary air removal ensures that when heating activates the adhesive properties, no air inclusions are generated, resolving the contradiction between bonding strength and absence of harmful factors.
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 prevents air inclusions and tensioning stresses, maintaining the optical and mechanical integrity of the layered glass, ensuring accurate positioning and enhanced transparency and mechanical properties.
Implementation Method 1
a vacuum heat treatment process to remove air from separation gaps
Implementation Method 2
heating and calendering processes to force the layers to adhere to each other and activate the adhesive properties of the thermoplastic resin
Implementation Method 3
the intermediate layer, generally flexible, covers and is in contact with the first internal surface in areas far from the three-dimensional macroscopic elements and, in correspondence of the latter, it is in contact only with a portion of the whole surface area of each of the three-dimensional macroscopic elements leaving a separating gap, containing air, around them
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2~3
AI summary
The present invention refers to a method for making a layered structure (10) without any defects, comprising a first support layer (12), a second support layer (14), and an adhesive intermediate layer (16) interposed between said first layer (12) and said second layer (14) which is adapted to fix said layers on each other. Said intermediate layer (16) embedding operatively at least a three-dimensional macroscopic element (18) being made of crystal glass or precious stones, and said intermediate layer (16) being made of a thermoplastic resin having a melting temperature (Tm).