Non-autoclave laminated glass

• US 20040182493A1
• Filed: 03/20/2003
• Published: 09/23/2004
• Est. Priority Date: 03/20/2003
• Status: Active Grant

• Current Assignee: Cardinal IG Company (Cardinal Glass Industries Incorporated)
• Original Assignee: Cardinal IG Company (Cardinal Glass Industries Incorporated)
• Inventors: Chick, James Allen
• Granted Patent: US 7,143,800 B2
• Time in Patent Office: Days
• US Class Current: 156/103
• CPC Class Codes: B32B 17/10036 comprising two outer glass sheets
• CPC Class Codes: B32B 17/10743 containing acrylate (co)polymers or salts thereof
• CPC Class Codes: B32B 17/10862 using pressing-rolls
• CPC Class Codes: B32B 17/10871 in combination with particular heat treatment
• CPC Class Codes: B32B 17/10935 as a preformed layer, e.g. formed by extrusion
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/14 Velocity, e.g. feed speeds
• CPC Class Codes: B32B 2315/08 Glass
• CPC Class Codes: B32B 37/18 involving the assembly of discrete sheets or panels only
• CPC Class Codes: Y10T 156/17 Surface bonding means and/or assemblymeans with work feeding or handling means
• CPC Class Codes: Y10T 156/1741 Progressive continuous bonding press [e.g., roll couples]

Abstract

The invention provides a non-autoclave method and apparatus for producing laminated glass. The method and apparatus provide a non-autoclave laminated glass process that is continuous and thus eliminates the batch processing of known autoclave processes. In addition, the method and equipment do not require vacuum processes, involving complicated vacuum bags, vacuum rings, or the like.

Claims

1. A method for producing non-autoclave laminated glass, the method comprising:

a) providing a laminated glass panel comprising a desired interlayer sandwiched between at least two sheet-like substrates;

b) providing a production line comprising a plurality of ovens each followed by at least one pair of confronting press members, wherein a substrate support defines a path of substrate travel extending along the production line; and

c) conveying the laminated glass panel along the path of substrate travel and operating the ovens and the press members, wherein operation of the ovens delivers heat to the laminated glass panel and brings it to a temperature of at least about 255 degrees Fahrenheit in a single pass along the path of substrate travel, and wherein operation of the press members applies pressure to the laminated glass panel.

2. The method of claim 1 wherein the production line comprises at least three ovens each followed by at least one pair of confronting press members, wherein the conveyance of the laminated glass panel comprises moving it through each of the ovens and between each pair of confronting press members.

3. The method of claim 1 wherein each of the ovens have independent temperature controls, the method comprising operating different ovens at different temperatures.

4. The method of claim 1 wherein the substrate support comprises a plurality of spaced-apart transport rollers, wherein the conveyance of the laminated glass panel comprises transporting it along the rollers.

5. The method of claim 4 wherein at least some of the transport rollers are operatively connected to variable speed motors, the method comprising conveying the laminated glass panel through different ovens at different rates.

6. The method of claim 4 wherein at least some of the transport rollers are operatively connected to one or more motors, the method comprising operating the thus-motorized rollers such that the laminated glass panel is conveyed along the path of substrate travel at an overall rate greater than about 15 feet per minute.

7. The method of claim 6 wherein the thus-motorized rollers are operated such that the laminated glass panel is conveyed along the path of substrate travel at an overall rate greater than about 20 feet per minute.

8. The method of claim 1 wherein the path of substrate travel has a length of at least about 50 feet, wherein the conveyance of the laminated glass panel comprises transporting it along substantially the entire length of the path of substrate travel.

9. The method of claim 1 wherein operation of a first of the pairs of confronting press members is performed while the laminated glass panel is at a temperature of between about 120 degrees Fahrenheit and about 140 degrees Fahrenheit.

10. The method of claim 9 wherein operation of a second of the pairs of confronting press members is performed while the laminated glass panel is at a temperature of between about 150 degrees Fahrenheit and about 170 degrees Fahrenheit.

11. The method of claim 10 wherein operation of a third of the pairs of confronting press members is performed while the laminated glass panel is at a temperature of between about 180 degrees Fahrenheit and about 200 degrees Fahrenheit.

12. The method of claim 11 wherein operation of a fourth of the pairs of confronting press members is performed while the laminated glass panel is at a temperature of between about 210 degrees Fahrenheit and about 230 degrees Fahrenheit.

13. The method of claim 12 wherein operation of a fifth of the pairs of confronting press members is performed while the laminated glass panel is at a temperature of between about 240 degrees Fahrenheit and about 260 degrees Fahrenheit.

14. The method of claim 13 wherein operation of a sixth of the pairs of confronting press members is performed while the laminated glass panel is at a temperature of between about 270 degrees Fahrenheit and about 290 degrees Fahrenheit.

15. The method of claim 1 wherein the production line includes between six and nine ovens each followed by at least one pair of confronting press members, wherein the conveyance of the laminated glass panel comprises moving it through each of the ovens and between the confronting press members.

16. The method of claim 1 wherein the confronting press members are nip rollers, and wherein the conveyance of the laminated glass panel comprises pressing it between each pair of confronting nip rollers.

17. The method of claim 16 wherein each pair of confronting nip rollers is operated to provide a foot path of at least about 0.5 inch on the laminated glass panel during a pressing operation.

18. The method of claim 17 wherein each pair of confronting nip rollers is operated to provide a foot path of at least about two inches on the laminated glass panel during a pressing operation.

19. The method of claim 16 wherein each pair of confronting nip rollers is mounted to provide a separation distance smaller than a thickness of the laminated glass panel by between about 0.05 inch and about 0.20 inch.

20. The method of claim 16 wherein the nip rollers are operatively coupled with 8 inch air cylinders that are operated to apply pressure via the nip rollers to the laminated glass panel during a pressing operation.

21. The method of claim 20 wherein the air cylinders are operated such that a pressure of between about 60 pounds per linear inch and about 120 pounds per linear inch is applied to the laminated glass panel.

22. The method of claim 21 wherein the air cylinders are operated such that a pressure of between about 80 pounds per linear inch and about 85 pounds per linear inch is applied to the laminated glass panel.

23. A production line for producing non-autoclave laminated glass, the production line comprising at least three ovens each followed by at least one pair of confronting press members between which laminated glass panels can be positioned during pressing operations, wherein a substrate support defines a path of substrate travel extending through the ovens and between each pair of confronting press members, and wherein the ovens are adapted for heating a laminated glass panel to a temperature of at least about 255 degrees Fahrenheit in a single pass along the path of substrate travel.

24. The production line of claim 23 wherein the ovens have independent temperature controls, such that different ovens can be operated at different temperatures.

25. The production line of claim 23 wherein the substrate support comprises a plurality of spaced-apart transport rollers.

26. The production line of claim 25 wherein at least some of the transport rollers are operatively connected to variable speed motors, such that the laminated glass panel can be conveyed through different ovens at different rates.

27. The production line of claim 25 wherein at least some of the transport rollers are operatively connected to one or more motors, the thus-motorized rollers being adapted to convey the laminated glass panel along the path of substrate travel at an overall rate greater than about 15 feet per minute.

28. The production line of claim 27 wherein the thus-motorized rollers are adapted to convey the laminated glass panel along the path of substrate travel at an overall rate greater than about 20 feet per minute.

29. The production line of claim 23 wherein the path of substrate travel has a length of at least about 50 feet.

30. The production line of claim 29 wherein the path of substrate travel has a length of between about 55 feet and about 95 feet.

31. The production line of claim 23 wherein a first of the ovens has a length of about 20 feet.

32. The production line of claim 31 wherein a second of the ovens has a length of about ten feet.

33. The production line of claim 32 wherein a third of the ovens has a length of about ten feet.

34. The production line of claim 33 wherein a fourth of the ovens has a length of about ten feet.

35. The production line of claim 34 wherein a fifth of the ovens has a length of about ten feet.

36. The production line of claim 35 wherein a sixth of the ovens has a length of about ten feet.

37. The production line of claim 23 wherein the line includes between six and nine ovens each followed by at least one pair of confronting press members between which laminated glass panels can be positioned during pressing operations.

38. The production line of claim 23 wherein the ovens are radiant ovens.

39. The production line of claim 38 wherein each oven comprises a plurality of spaced-apart heating elements, the heating elements being positioned below and/or above the path of substrate travel.

40. The production line of claim 39 wherein at least some of the heating elements are quartz tube heating elements.

41. The production line of claim 23 wherein the confronting press members are nip rollers.

42. The production line of claim 41 wherein each pair of confronting nip rollers is mounted to provide a separation distance that is smaller than a thickness of the laminated glass panel.

43. The production line of claim 42 wherein the separation distance is smaller than the thickness of the desired laminated glass panel by between about 0.05 inch and about 0.2 inch.

44. The production line of claim 41 wherein each pair of confronting nip rollers is adapted to provide a foot path of at least about 0.5 inch on the laminated glass panel during a pressing operation.

45. The production line of claim 44 wherein each pair of confronting nip rollers is adapted to provide a foot path of at least about two inches on the laminated glass panel during a pressing operation.

46. The production line of claim 41 wherein the nip rollers are operatively coupled with air cylinders that are adapted for applying pressure via the nip rollers to the laminated glass panel during a pressing operation.

47. A method for producing non-autoclave laminated glass, the method comprising:

a) providing a laminated glass panel comprising an ionoplast interlayer sandwiched between at least two sheet-like substrates;

b) providing a production line comprising a plurality of ovens each followed by at least one pair of confronting press members, wherein a substrate support defines a path of substrate travel extending along the production line; and

c) conveying the laminated glass panel along the path of substrate travel and operating the ovens and the press members, wherein operation of the ovens delivers heat to the laminated glass panel and brings it to a temperature of at least about 255 degrees Fahrenheit in a single pass along the path of substrate travel, and wherein operation of the press members applies pressure to the laminated glass panel.