Load Bearing Inserts for Glass Laminates
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Solution Overview
Problem
Existing methods for assembling laminate panels, particularly glass laminates, face challenges with jointing techniques that apply loads, leading to delamination issues due to the bonding layer creeping under pressure, which affects the appearance and structural integrity of the laminate.
Innovation Solution
A method involving the placement of a seal around bores in the laminate before lamination to exclude the bonding layer from the bore area, allowing a load-bearing insert to be positioned within the void created, which can be filled with a material that sets to provide structural support and prevent delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If clamping plates joined by bolts are used to attach laminate panels, then the panels can be securely fastened to supporting structures, but the bonding layer creeps under the load which detracts from appearance and may have detrimental consequences
Solution Approach 1:
The patent divides the bonding interface into two separate zones: a load-bearing zone with direct contact between clamping plates and glass surfaces, and a bonding zone with PVB interlayer. This segmentation allows each zone to perform its specific function without compromising the other, resolving the contradiction between fastening strength and bonding stability
Solution Approach 2:
The patent introduces an intermediary component (load-bearing insert or rigid interlayer) between the clamping plate and the PVB bonding layer. This intermediary transfers the mechanical load away from the bonding layer, preventing creep while maintaining secure fastening. The intermediary acts as a mediator that decouples the conflicting requirements of strength and reliability
2Ease of manufacture
If a fixing assembly is positioned in a bore and fixed using casting resin, then the laminate can be joined to adjacent structure, but the solution is difficult to put into practice and is not entirely effective
Solution Approach 1:
The patent applies preliminary action by pre-positioning load-bearing inserts or rigid interlayers during the lamination process before final assembly. This ensures proper placement and alignment, eliminating the need for complex post-lamination adjustments with casting resin. The preliminary placement of load-bearing components simplifies the manufacturing process while ensuring reliable load transfer
3Strength
If load is applied across the laminate during clamping, then the panels can be securely attached, but the bonding layer creeps under the load affecting appearance and structural integrity
Solution Approach 1:
The patent segments the load path to separate bonding function from load-bearing function. The PVB layer is confined to areas not subjected to clamping loads, maintaining laminate flatness and appearance. Load-bearing inserts or rigid interlayers handle the mechanical loads, preventing PVB creep and maintaining manufacturing precision
Solution Approach 2:
The patent applies local quality by creating different functional zones within the laminate structure. Areas with load-bearing inserts have rigid, load-resistant properties, while areas with PVB bonding maintain flexibility and adhesive properties. This local differentiation allows the laminate to simultaneously achieve strong attachment and maintain flatness
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 significantly reduces delamination, accommodates variations in bonding layer thickness, and enhances the production of laminates with improved mechanical properties, particularly suitable for architectural applications.
Implementation Method 1
a seal is positioned between the plies so as to surround the bore or bores thereby excluding the bonding interlayer from an area surrounding the bore or bores
Implementation Method 2
A load bearing insert may be positioned in the void defined by the plies and the seal
Implementation Method 3
laminated panel comprising a first glass ply, a second glass ply and a bonding interlayer
Data Source
AI summary
Laminates comprising at least two glass plys surrounding at least one interlayer having at least one bore extending through the laminate are produced by excluding the interlayer from the area surrounding the bore(s) and positioning a load bearing insert around the bore. The insert may be positioned before or after the laminating process. The invention reduces the tendency for delamination around the area of the bore when the laminate is placed under load.