Soft Chemically Strengthenable Glass for Pair Sagging
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Solution Overview
Problem
Existing glass compositions used in laminates for automotive and architectural applications face challenges in pair sagging due to viscosity differences, leading to increased manufacturing costs and shape mismatches, especially when combining soda lime glass with aluminosilicate glasses, which require separate sagging steps and consume more energy and time.
Innovation Solution
Development of glass compositions with specific ranges of SiO2, Al2O3, R2O, P2O5, B2O3, and water content that allow for pair sagging with soda lime glass, maintaining fusion formability and strengthening capabilities, while reducing optical distortions and shape mismatches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate sagging steps are used for soda lime glass and aluminosilicate glass, then shape accuracy is maintained, but manufacturing time and energy consumption increase
Solution Approach 1:
The patent combines two separate sagging operations into a single simultaneous sagging process by coordinating the heating of both glass types to their respective sag temperatures together. This merging of operations reduces manufacturing time while maintaining shape accuracy through synchronized process control.
Solution Approach 2:
The patent modifies the heating parameters and temperature profiles to enable both soda lime glass and aluminosilicate glass to sag simultaneously at different temperatures within the same furnace environment. By changing and coordinating multiple thermal parameters, the process achieves both time efficiency and shape precision.
2Manufacturing precision
If separate sagging steps are used for soda lime glass and aluminosilicate glass, then shape control is improved, but energy consumption increases
Solution Approach 1:
The patent merges two separate heating and sagging cycles into one simultaneous process, consolidating energy consumption into a single thermal event. This reduces total energy usage while maintaining shape control through coordinated temperature management of both glass types.
Solution Approach 2:
The patent creates a universal sagging process that handles both soda lime glass and aluminosilicate glass simultaneously in a single furnace operation. This multi-functional approach eliminates the need for separate energy-intensive sagging cycles while maintaining precise shape control for both glass types.
3Strength
If aluminosilicate glass is chemically strengthened, then strength is improved, but compressive stress depth is insufficient for thin articles
Solution Approach 1:
The patent modifies the chemical strengthening parameters by adjusting ion exchange conditions (temperature, time, composition) to achieve both high surface compressive stress and adequate depth penetration in thin glass articles. By changing these parameters, the process overcomes the limitation of insufficient stress depth.
Solution Approach 2:
The patent uses a composite ion exchange approach combining multiple alkali metal ions (potassium, sodium, cesium) in specific proportions to create a gradient compressive stress profile that achieves both high surface strength and sufficient depth penetration in thin aluminosilicate glass articles.
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 new glass compositions enable efficient pair sagging with soda lime glass, reducing manufacturing time and costs, and maintaining strength and optical clarity in laminates for automotive and architectural applications.
Implementation Method 1
viscosity differences, leading to increased manufacturing costs and shape mismatches
Implementation Method 2
heating the stack of glass articles to a temperature ('sag temperature') at which the glasses sag together to the desired shape
Implementation Method 3
chemically strengthened, SLG articles do not exhibit sufficient strength attributes (in terms of compressive stress and depth of compressive stress)
Data Source
AI summary
Disclosed herein are embodiments of a glass article having a glass composition. The glass composition includes SiO2 in an amount of from 63 mol % to 75 mol %, Al2O3 in an amount of from 7 mol % to 13 mol %, R2O in an amount of from 13 mol % to 24 mol %, P2O5 in an amount of from 0.1 mol % to 1.2 mol %, and a water content β-OH of 0.1 abs/mm to 0.5 abs/mm. Further, the glass composition includes at least one of MgO or ZnO. MgO is present in a range from 0 mol % to 7 mol %, and ZnO is present in a range from 0 mol % to 7 mol %. The glass article has an anneal point and a softening point, and the relationship of (anneal point+softening point)/2 is less than 685° C.