Window Laminate Repair via Vacuum Heating and Adhesive Injection
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Solution Overview
Problem
Window laminates tend to delaminate over time, leading to moisture ingress and subsequent fogging and reduced transparency, with existing methods being costly and ineffective in fully repairing delamination and moisture removal.
Innovation Solution
A method involving placing the laminate in a vacuum bag and heating it in an oven or autoclave, followed by injecting adhesive into delamination voids using a syringe and needle, and optionally replacing and repairing the polyvinyl butyral layer if initial repairs are insufficient.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If window laminates are used for extended periods, then they provide durable protection, but they tend to delaminate and allow moisture ingress over time
Solution Approach 1:
The patent applies preliminary action by heating the window laminate in an oven or autoclave before adhesive injection. This pre-heating step softens the existing adhesive and prepares the laminate structure for effective adhesive re-injection, preventing future delamination by ensuring proper adhesive bonding conditions are established in advance
Solution Approach 2:
The patent utilizes parameter changes by controlling temperature and pressure conditions during the repair process. The laminate is heated to specific temperature ranges (e.g., 100-150°C) and subjected to pressure in an autoclave to restore adhesive bonding. These parameter changes enable the adhesive to properly bond the plies together, preventing delamination while maintaining long-term reliability
2Reliability
If delamination occurs and moisture enters the void, then the structural integrity deteriorates, but complete removal of moisture and full repair is difficult with existing methods
Solution Approach 1:
The patent applies the extraction principle by removing moisture from the delaminated void through heating and vacuum processes. The oven or autoclave heating evaporates trapped moisture, and the vacuum system extracts it from the laminate structure. This extraction of the harmful moisture element enables complete repair and restoration of structural integrity
Solution Approach 2:
The patent uses an intermediary approach by injecting new adhesive into the delaminated void as a mediating substance. This adhesive acts as an intermediary that bonds the separated plies together, filling the void and creating a new bonding interface that restores structural integrity while being more effective than the degraded original adhesive
3Reliability
If the entire window laminate structure is replaced instead of repaired, then reliability is restored, but the cost becomes substantially higher
Solution Approach 1:
The patent applies discarding and recovering by removing only the degraded adhesive layers and moisture from the laminate structure, while retaining and reusing the original glass plies and laminate structure. This selective discarding of only the defective components (old adhesive and moisture) and recovery of the valuable structural elements achieves cost-effective repair while restoring full reliability
Solution Approach 2:
The patent uses parameter changes (temperature, pressure, adhesive composition) to restore the bonding properties of the laminate without replacement. By controlling these parameters during heating and adhesive injection, the original structure is rejuvenated with restored adhesive bonding, achieving reliability restoration at fraction of replacement cost
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
Effectively repairs delaminated areas, removes moisture, and restores the structural integrity and transparency of window laminates at a lower cost than replacement, applicable to various types of windows including aircraft and bullet-resistant windows.
Implementation Method 1
inserting it into an oven or autoclave for a specific ramp up/hold and ramp down, depending on the severity of the delamination or moisture presented
Implementation Method 2
inserting it into an oven or autoclave for a specific ramp up/hold and ramp down
Implementation Method 3
The adhesive is injected into the delaminated area to fill the void between plies and prevent moisture or delamination from returning
Data Source
AI summary
A method for repairing window laminates in which two plies have become separated to create a void, and wherein moisture may have entered through an edge of the window laminate and into the void. The method includes the steps of: placing the window laminate in a vacuum bag and inserting the vacuum bag containing the window laminate into an oven or autoclave for a minimum of ten minutes at a minimum temperature of 120 degrees Fahrenheit to remove the moisture between the plies; removing the vacuum bag and window laminate from the oven, and removing the window from the vacuum bag; forcing a needle on a syringe through the edge of the window laminate in the area of the void; and injecting an adhesive in the syringe into the void to fill the void with the adhesive.