Vacuum-Assisted Microwave Lamination of Composite Panes
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Solution Overview
Problem
Autoclave-free lamination processes for composite panes often result in insufficient connections and air inclusions, leading to subpar quality, especially in the automotive sector, and are energy-intensive.
Innovation Solution
A method involving a vacuum-assisted process with microwave heating to laminate composite panes without an autoclave, using a stack sequence of substrate and cover panes with an intermediate layer, where the sequence is vented and heated under controlled pressure and temperature conditions to ensure effective bonding and minimize air inclusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If autoclave-free lamination processes are used, then energy consumption is reduced and process time is shortened, but bonding quality deteriorates and air inclusions occur
Solution Approach 1:
The lamination process is divided into distinct phases: initial vacuum sealing at room temperature, controlled heating to melting point, sustained vacuum application during cooling. Each phase addresses specific bonding requirements, ensuring complete edge sealing and air evacuation while maintaining energy efficiency without autoclave equipment
Solution Approach 2:
The process dynamically adjusts temperature parameters from room temperature to above the melting point of the intermediate layer, then controls cooling rate. Vacuum pressure is maintained throughout the heating and cooling phases to prevent air inclusion, while the heating power is modulated to achieve uniform temperature distribution across the laminate edges
2Reliability
If autoclave processes are used, then bonding quality is improved, but energy consumption increases and process time lengthens
Solution Approach 1:
The invention extracts and eliminates the autoclave component from the lamination process. Instead of using high-pressure autoclave equipment, the process relies on controlled atmospheric pressure combined with sustained vacuum application during critical phases, achieving equivalent or superior bonding quality without the energy-intensive autoclave system
Solution Approach 2:
The mechanical autoclave pressure system is replaced with a vacuum-based system. The vacuum pump creates negative pressure to evacuate air from the laminate edges during heating and cooling, substituting the need for high-pressure mechanical containment while reducing overall energy consumption
3Device complexity
If autoclave-free processes are used, then process complexity is reduced, but manufacturing precision deteriorates due to air inclusions and edge clouding
Solution Approach 1:
The process applies vacuum sealing at room temperature before heating, pre-evacuating air from the laminate edges and sealing them in place. This preliminary action prevents air inclusion during subsequent heating phases, ensuring clear edges and high manufacturing precision without complex equipment
Solution Approach 2:
Vacuum application is maintained continuously throughout the heating and cooling phases, not just intermittently. This continuous vacuum action ensures consistent air evacuation and prevents edge clouding, maintaining high manufacturing precision throughout the entire process while using simple equipment
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 method produces high-quality composite panes with improved transparency, clarity, and strength while being energy-efficient and cost-effective, eliminating the need for energy-intensive autoclave processes.
Implementation Method 1
Applying a vacuum ring or vacuum bag around the stack sequence
Implementation Method 2
whereby the stacking sequence is maintained by microwave radiation at a temperature T3 of 70°C to 130°C
Data Source
Figure 1
Figure 2
Figure 3(A)~3(B)
AI summary
The invention relates to a method for laminating a composite pane (30), wherein: (a) a stack sequence (1) of a substrate pane (2), at least one intermediate layer (3), and a cover layer (4) is produced, (b1) a vacuum ring (5) or a vacuum bag is placed around the stack sequence (1), (b2) air is removed from the stack sequence (1) by applying a negative pressure p1 which is less than or equal to 0.3 bar to the vacuum ring (5) or the vacuum bag for a duration t1 which is more than or equal to 8 min and at a temperature T1 of 0 °C to 30 °C, (b3) the stack sequence (1) is heated to a temperature T2 of 70 °C to 130 °C by means of microwave radiation, wherein the vacuum ring (5) or the vacuum bag is kept at a negative pressure P2 which is less than or equal to 0.3 bar, (b4) the stack sequence (1) is kept at a temperature T3 of 70 °C to 130 °C by means of microwave radiation and air is removed by applying a negative pressure p3 which is less than or equal to 0.3 bar to the vacuum ring (5) or the vacuum bag for a duration t3 which is more than or equal to 8 min, (b5) the stack sequence (1) is cooled to a temperature T4 of less than 70 °C, and the vacuum ring (5) or the vacuum bag is kept at a negative pressure p4 which is less than or equal to 0.3 bar, and (b6) the vacuum ring (5) or the vacuum bag is supplied with air, and (c) the vacuum ring (5) or the vacuum bag is removed.