AU2012291917A1

AU2012291917A1 - Process for manufacturing a glazing unit having a decorative effect

Info

Publication number: AU2012291917A1
Application number: AU2012291917A
Authority: AU
Inventors: Erwan BAQUET; Aurelien Gouy; Fabien Levasseur; Jean-Francois Outin
Original assignee: Saint Gobain Glass France SAS; Compagnie de Saint Gobain SA
Current assignee: Saint Gobain Glass France SAS
Priority date: 2011-08-04
Filing date: 2012-07-31
Publication date: 2015-01-22
Anticipated expiration: 2032-07-31
Also published as: EP2821224B1; FR2978698A1; FR2978698B1; EP2739472B1; PL2821224T3; WO2013017797A1; EP2739472A1; PL2739472T3; AU2012291917B2; EP2821224A1; TR201907524T4

Abstract

The present invention relates to a process for manufacturing a laminated glazing comprising a core (1) at least one of the faces of which is connected to an external glass substrate (3) via a lamination interlayer, characterized in that the core (1) consists of a 3D textile layer.

Description

PROCESS FOR MANUFACTURING A GLAZING UNIT HAVING A DECORATIVE EFFECT 5 The present invention relates to a glazing unit, especially a decorative glazing unit, combining both the esthetics of the three-dimensional aspect of certain textile coatings and the durability of glazing substrates. It also relates to a process for 10 manufacturing such glazing units. Different types of glazing units that are made from laminated products, and that comprise a decorative element encapsulated between two glass sheets, are known. 15 Thus, an assembly consisting of a stone "laminate", each of the faces of which is joined to a glass sheet by an intermediate film, has been proposed. An assembly in which the stone laminate is replaced by a printed image has also been proposed. 20 Lastly, patent JP 2001226154 provides a laminated glazing unit consisting of a layer of wool or fibers that is sandwiched between two glass panes. Such a glazing unit is intended to serve two functions, namely on the one hand to filter ultraviolet radiation, and on 25 the other hand to prevent the glass sheets from shattering when struck. Moreover, certain textile coatings are known the esthetic character of which comes from their structure itself, which is to say that their thickness plays a 30 pivotal role in their esthetic aspect. Three dimensional or 3D textile products will be spoken of below. These textile coatings are particularly advantageous insofar as their esthetic aspect may take 35 an extremely wide variety of forms, and insofar as they give glazing units a striking three-dimensional aspect. None of the laminated glazing units mentioned above allows the 3D aspect of such textile coatings to be displayed to good effect.

- 2 One of the difficulties encountered when attempting to form a laminated glazing unit encapsulating 3D textile coatings is that the latter possess a particularly fragile texture that, when 5 subjected to conventional encapsulation methods, is crushed under the vacuum that is necessarily applied to them, to the point that they thus lose their 3D character that is their essential advantage from the esthetic standpoint. 10 The aim of the present invention is to provide a process allowing such crushing to be avoided, and laminated glazing units comprising a core made of a 3D textile material that preserves its three-dimensional aspect after the encapsulation operation to be 15 produced. Thus, one subject of the present invention is a laminated glazing unit comprising a core at least one of the faces of which is joined to an external glazing substrate by a lamination interlayer, characterized in 20 that the core consists of a 3D textile coating. According to the invention, one or both external faces of the glazing unit will possibly consist of a glazing substrate. Another subject of the present invention is a 25 process for manufacturing a laminated glazing unit comprising a core at least one of the faces of which is joined to a glazing substrate by a lamination interlayer made of EVA or PVB, characterized in that it comprises: 30 - a step of joining an assembly consisting of said glazing substrate and said lamination interlayer to a core consisting of a 3D textile coating; and - a step formed from a plurality of phases comprising a heating phase, a temperature maintenance 35 phase and a phase of cooling said assembly and, simultaneously, a phase of applying a vacuum, a vacuum maintenance phase and a phase of returning said assembly to ambient pressure following a specific temperature/pressure profile such that when the lamination interlayer is made of EVA the vacuum is applied during at least part of the heating phase and, when the lamination interlayer is made of PVB, the 5 phase of applying a vacuum is implemented during at least part of the temperature maintenance phase. The lamination interlayer will possibly be made of EVA and, under these conditions, the heating phase will possibly be implemented with an upward temperature 10 slope of about 2.74C/min. Next, the temperature maintenance phase will possibly be carried out between 1000C and 1400C and preferably at about 1300C. The cooling phase will possibly be implemented with a downward temperature slope of about 2.74C/min. The 15 phase of applying a vacuum will possibly be implemented with a downward pressure slope of about 0.8x10 4 Pa/min and the vacuum maintenance phase will possibly be carried out between 0.5x10 4 Pa and 2x10 4 Pa and preferably at about 1x10 4 Pa. Moreover, the phase of 20 returning to ambient pressure will possibly be implemented with a slope of about 0.8x10 4 Pa/min. The phase of applying a vacuum will possibly start at the same time as the heating phase and the phase of returning to ambient pressure will possibly start at 25 the end of the heating phase. The phase of applying a vacuum will also possibly start substantially in the middle of the heating phase. The lamination interlayer will possibly be made of PVB and, under these conditions, the heating phase will 30 possibly be implemented with an upward temperature slope of about 2.6 0 C/min. Next, the temperature maintenance phase will possibly be carried out between 700C and 1000C and preferably at about 800C. The cooling phase will possibly be implemented with a 35 downward temperature slope of about 2.60C/min. The phase of applying a vacuum will possibly be implemented with a downward pressure slope of about 0.8x104 Pa/min and the vacuum maintenance phase will possibly be - 4 carried out between 1x10 4 Pa and 3x10 4 Pa and preferably at about 2xlO 4 Pa. Moreover, the phase of returning to ambient pressure will possibly be implemented with a slope of about 0 .8x10 4 Pa/min. The phase of applying a 5 vacuum will possibly start at the same time as the heating phase and substantially half of the vacuum maintenance phase will possibly take place during the heating phase and half during the temperature maintenance phase. The phase of applying a vacuum will 10 also possibly start at the end of the heating phase and the vacuum maintenance phase will possibly take place substantially during the temperature maintenance phase. The present invention is particularly advantageous in that it allows a glazing unit to be provided the 15 esthetic aspect of which is extremely similar to that provided by the textile material itself, while benefiting from the protection provided by the glass sheets from dust and various aggressions. As a variant of the invention, a lamination 20 interlayer able to filter ultraviolet radiation may be used, so that the latter protects the textile material from solar aggressions liable to modify its esthetic qualities over time. A method of implementing the present invention 25 will be described below, by way of nonlimiting example, with reference to the appended drawings in which: - figure 1 is a transverse cross-sectional view of a glazing unit according to the invention; - figures 2 and 3 are graphs of temperature and 30 pressure as a function of time showing the heating/cooling profiles and the vacuum application/return to ambient pressure profiles of two embodiments of the invention using EVA as a lamination interlayer; 35 - figures 4 and 5 are graphs of temperature and pressure as a function of time showing the heating/cooling profiles and the vacuum application/return to ambient pressure profiles of two embodiments of the invention using PVB as a lamination interlayer; and - figure 6 is a transverse cross-sectional view showing a variant of the glazing unit according to the 5 invention shown in figure 1, In a first embodiment of the present invention, and as shown in figure 1, it is desired to encapsulate a 3D textile material 1 between two glazing substrates 3. To do this, two lamination interlayers 5 made of 10 ethylene vinyl acetate, called EVA below, are used. In the conventional way a sandwich consisting of the 3D textile material 1 between the two sheets 5 of the EVA interlayer material 5, which is itself placed between the two glazing substrates 3, is placed in a 15 chamber in which temperature and pressure conditions can be controlled. Figure 2 shows the pressure (dashed curve)/temperature (solid curve) profile applied to the assembly as a function of time over a manufacturing 20 cycle. In a first phase a of the process the assembly is heated with a temperature slope of about 2.70C/min until the crosslinking temperature of the interlayer material 5, which is about 1300C, is reached. Next, in 25 a phase b this temperature is maintained for about 150 mins, then the assembly is left to cool, in a phase c, to room temperature with a cooling slope similar to that of the temperature increase. During the heating phase a the pressure inside the 30 chamber is gradually decreased, during a phase a', so as to remove the products of outgassing from the interlayer material, until a pressure of about 1x10 4 Pa is reached with a slope of about 0.8x10 4 Pa/min. Next, during a phase b', this pressure is maintained 35 substantially throughout the phase a of temperature increase, then the pressure is gradually increased, during a phase c', with a slope similar to the preceding one until atmospheric pressure is reached.

- 6 Next, this pressure is maintained, during a phase d', until the end of the cycle at about 250 mins. It will be noted that such a temperature and pressure profile allows all the products of outgassing 5 from the interlayer material to be removed, and therefore the formation of gas bubbles in the product to be prevented, while preventing crushing of the textile material 1, which thus preserves all of its esthetic qualities. 10 in another embodiment of the invention the pressure/temperature profile as a function of time shown in figure 3 is used. The temperature characteristics of this profile are unchanged. As regards the pressure profile, in a 15 phase a' about half the temperature rise time (phase a) i.e. about 25 mins, is waited before the pressure inside the chamber is gradually decreased, in a phase b', and moreover a temperature profile equal to the preceding profile is applied. 20 It has been observed that such a pressure/temperature profile also allows the products of outgassing to be satisfactorily removed and crushing of the textile material 1 to be prevented. Thus, according to the invention it is essential 25 to create a vacuum that allows the products of outgassing to be pumped away during at least part of the phase in which the temperature of the product is increased. It is possible, according to the invention, to use 30 another type of interlayer material, namely polyvinyl butyral, called PVB below. It has been observed that, all other things being equal, the pressure/temperature profile is then notably different from that implemented with EVA. 35 Such a profile is shown in figure 4. It will be noted that in a phase a the assembly is gradually heated from room temperature until the crosslinking temperature of PVB, i.e. about 800C, is reached with an -7 upward temperature slope of about 2.60C/min. Next, in a phase b, this temperature is maintained for about 50 mins before the assembly is cooled, in a phase c, to room temperature with a cooling slope similar to the 5 heating slope. At the same time, in a phase a', the pressure in the chamber is decreased until a pressure of about 2x10 4 Pa is reached, then the latter is maintained, in a phase b', until the end of the temperature increase and 10 beyond, in fact for about a third of the phase b of the heating plateau. Next, the pressure is raised to atmospheric pressure with a slope similar to the slope with which the vacuum was applied. Atmospheric pressure is then maintained until the end of the cycle. 15 It has been observed that such a profile allows, as in the preceding case, gas that desorbs from the PVB to be pumped away while simultaneously maintaining the 3D structure of the textile material. In another embodiment of the present invention, as 20 shown in figure 5, the application of a vacuum to the assembly is shifted in time, in a phase a', to the end of the phase of temperature increase a, and the vacuum is maintained in the chamber, in a phase c, throughout the temperature increase phase b. Next, pressure is re 25 established in the chamber during a phase d' Thus, it will be noted that in the case where PVB is used as the interlayer material, it is essential to decrease pressure during at least part of the plateau where the temperature of the assembly is maintained. 30 As a variant embodiment of the invention, shown in figure 6, the glazing unit comprises only one external glazing substrate 3, so that one of the faces la of the textile material 1 is located in open air. Such an embodiment of the invention is advantageous in that it 35 allows, while protecting one of the faces of the textile, direct visual and tactile access to its other face.

- 8 The glazing substrate 3 may of course be of various natures and may especially be made of clear glass, coated glass, tinted glass, mirror glass, etc.

Claims

1. A process for manufacturing a laminated glazing 5 unit comprising a core (1) at least one of the faces of which is joined to a glazing substrate (3) by a lamination interlayer (5) made of EVA or PVB, characterized in that it comprises: - a step of joining an assembly consisting of said 10 glazing substrate and said lamination interlayer to a core consisting of a 3D textile coating; and - a step formed from a plurality of phases comprising a heating phase, a temperature maintenance phase and a phase of cooling said assembly and, 15 simultaneously, a phase of applying a vacuum, a vacuum maintenance phase and a phase of returning said assembly to ambient pressure following a specific temperature/pressure profile such that when the lamination interlayer is made of EVA the vacuum is 20 applied during at least part of the heating phase and, when the lamination interlayer is made of PVB, the phase of applying a vacuum is implemented during at least part of the temperature maintenance phase. 25

2. The process for manufacturing a glazing unit as claimed in claim 1, in which the lamination interlayer is made of EVA, characterized in that the heating phase is implemented with an upward temperature slope of about 2.70C/min. 30

3. The process for manufacturing a glazing unit as claimed in claim 2, characterized in that the temperature maintenance phase is carried out between 100 0 C and 1400C and preferably at about 1300C. 35

4. The process for manufacturing a glazing unit as claimed in either of claims 2 and 3, characterized in - 10 that the cooling phase is implemented with a downward temperature slope of about 2.70C/min.

5. The process for manufacturing a glazing unit as S claimed in one of claims 2 to 4, characterized in that the phase of applying a vacuum is implemented with a downward pressure slope of about 0.8x10 4 Pa/min.

6. The process for manufacturing a glazing unit as 10 claimed in one of claims 2 to 5, characterized in that the vacuum maintenance phase is carried out between 0.5x10 4 Pa and 2x10 4 Pa and preferably at about 1x10 4 Pa. 15

7. The process for manufacturing a glazing unit as claimed in one of claims 2 to 6, characterized in that the phase of returning to ambient pressure is implemented with a slope of about 0.8x10 4 Pa/min. 20

8. The process for manufacturing a glazing unit as claimed in one of claims 2 to 7, characterized in that the phase of applying a vacuum starts at the same time as the heating phase. 25

9. The process for manufacturing a glazing unit as claimed in claim 8, characterized in that the phase of returning to ambient pressure starts at the end of the heating phase. 30

10. The process for manufacturing a glazing unit as claimed in one of claims 2 to 7, characterized in that the phase of applying a vacuum starts substantially in the middle of the heating phase. 35

11. The process for manufacturing a glazing unit as claimed in claim 1, in which the lamination interlayer is made of PVB, characterized in that the heating phase is implemented with an upward temperature slope of about 2.6C/min.

12. The process for manufacturing a glazing unit 5 as claimed in claim 11, characterized in that the temperature maintenance phase is carried out between 700C and 1000C and preferably at about 800C.

13. The process for manufacturing a glazing unit 10 as claimed in either of claims 11 and 12, characterized in that the cooling phase is implemented with a downward temperature slope of about 2.60C/min.

14. The process for manufacturing a glazing unit 15 as claimed in one of claims 11 to 13, characterized in that the phase of applying a vacuum is implemented with a downward pressure slope of about 0.8x10 4 Pa/min.

15. The process for manufacturing a glazing unit 20 as claimed in one of claims 11 to 14, characterized in that the vacuum maintenance phase is carried out between 1x10 4 Pa and 3x104 Pa and preferably at about 2x104 Pa. 25

16. The process for manufacturing a glazing unit as claimed in one of claims 11 to 15, characterized in that the phase of returning to ambient pressure is implemented with a slope of about 0.8x10 4 Pa/min. 30

17. The process for manufacturing a glazing unit as claimed in one of claims '1 to 16, characterized in that the phase of applying a vacuum starts at the same time as the heating phase. 35

18. The process for manufacturing a glazing unit as claimed in claim 17, characterized in that substantially half of the vacuum maintenance phase - 12 takes place during the heating phase and half during the temperature maintenance phase.

19. The process for manufacturing a glazing unit 5 as claimed in one of claims 11 to 16, characterized in that the phase of applying a vacuum starts at the end of the heating phase.

20. The process for manufacturing a glazing unit 10 as claimed in claim 19, characterized in that the vacuum maintenance phase takes place substantially during the temperature maintenance phase.