Prismatic Glass Laminate Segmentation for Crack Resistance
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Solution Overview
Problem
Conventional prismatic glass laminates face challenges in achieving a flat and polished surface finish, are prone to cracking during lamination, and have difficulty in maintaining structural integrity and preventing shard dislodgment due to thickness variations and external stresses.
Innovation Solution
A prismatic glass laminate configuration with a substrate and multiple prismatic glass elements bonded using laminating interlayers on both mounting and lateral surfaces, allowing for efficient manufacturing, enhanced structural integrity, and reduced thickness, while minimizing crack propagation and shard detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single large prismatic glass element is used, then the prismatic effect is achieved, but the glass is prone to cracking during lamination and has difficulty maintaining structural integrity
Solution Approach 1:
The patent divides the prismatic glass structure into multiple separate prismatic glass elements (first, second, third, and fourth elements) arranged in a sequence. Each element is bonded to adjacent elements through laminating interlayers, creating a modular structure that maintains the prismatic effect while improving manufacturability and structural reliability by distributing stresses across multiple smaller units rather than one large fragile piece.
2Weight of moving object
If the prismatic glass element is made thinner to reduce weight, then ease of installation improves, but the glass becomes more prone to fracture under wind loads
Solution Approach 1:
The patent creates a composite structure by bonding multiple prismatic glass elements together with laminating interlayers. This composite construction allows the use of thinner individual glass elements (reducing weight) while the collective assembly maintains structural strength through the distributed bonding system. The interlayers provide additional bonding strength and crack propagation resistance, enabling the use of thinner glass that would be too fragile if used alone.
3Ease of manufacture
If conventional lamination is used, then bonding is achieved, but cracks can propagate to edges causing large shards to become dislodged
Solution Approach 1:
The patent introduces additional laminating interlayers at the lateral surfaces between adjacent prismatic glass elements, creating multiple bonding planes throughout the structure. This segmentation of the bonding system ensures that if a crack develops in one element or at one bonding interface, the crack propagation is contained and prevented from reaching the outer edges where shards could become dislodged. The multiple interlayers create redundant bonding paths that maintain structural integrity.
4Shape
If faceted glass is used to achieve prismatic effect, then the decorative function is achieved, but the thickness variations make it difficult to toughen while maintaining flatness
Solution Approach 1:
The patent divides the faceted prismatic structure into multiple separate elements, each with its own facets. This segmentation allows each individual element to be tougher (tempered) separately while maintaining its faceted shape, and then bonded together to form the complete prismatic structure. The lateral bonding surfaces are designed to be substantially flat to ensure proper bonding, while the outer faceted surfaces maintain the decorative prismatic effect. This approach resolves the conflict between achieving faceted geometry and maintaining flatness for toughening.
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 configuration enables precise grinding and polishing, maintains structural integrity, reduces the risk of cracking, and enhances safety by preventing large glass shards from becoming dislodged, thus improving the prismatic effect and durability of the laminate.
Implementation Method 1
a first laminating interlayer is applied to a mounting surface of the prismatic glass element, the first laminating interlayer providing adhesion of the prismatic glass element to the substrate; a second laminating interlayer is applied to a lateral surface of the first prismatic glass element between adjacent prismatic glass elements, the second laminating interlayer providing adhesion of the first prismatic glass element to the lateral surface of an adjacent prismatic glass element
Implementation Method 2
glass with machined surfaces of relatively large area and optically flat but polished to generate a prismatic effect. The prisms refract light rays and change their direction
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
A prismatic glass laminate comprising: (a) a substrate; and (b) a plurality of prismatic glass elements mounted on said substrate, each element comprising: (i) a mounting surface to which a laminating interlayer is applied, said laminating interlayer providing adhesion of said element to the substrate; and (ii) a lateral surface to which a laminating interlayer is applied, said laminating interlayer providing adhesion of said element to the lateral surface of an adjacent element.