CN102329087B - 边部结构一体化夹层玻璃及其制造方法 - Google Patents

边部结构一体化夹层玻璃及其制造方法 Download PDF

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CN102329087B
CN102329087B CN201110170302XA CN201110170302A CN102329087B CN 102329087 B CN102329087 B CN 102329087B CN 201110170302X A CN201110170302X A CN 201110170302XA CN 201110170302 A CN201110170302 A CN 201110170302A CN 102329087 B CN102329087 B CN 102329087B
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laminated glass
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CN102329087A (zh
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欧迎春
肖昊江
朱治国
左岩
张延芳
郑善志
黄志文
孙皓天
朱银锤
魏川
丁方政
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China Building Materials Academy CBMA
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Abstract

本发明一种边部结构一体化夹层玻璃及其制造方法，该夹层玻璃包括两块或多块单片玻璃及夹设在相邻两块单片玻璃之间的胶片，胶片夹设在单片玻璃的中心区域，单片玻璃之间的边部区域为填充部，填充部宽度为20～50mm。本发明玻璃整体仍是夹层玻璃，仅在边部区域填充固化后有一定刚度的物质，提高边部胶片层的刚度，使边部玻璃各层的力学性能近似、粘结力提高，外力可以较为容易从最外面一层传递到内层，或从最内面一层传递到外层，并且边部各层较容易被破坏或与整体分离，可应用于航空、建筑、汽车、机车等领域有逃生或其它边部有刚度要求的门、窗或外墙中。

Description

边部结构一体化夹层玻璃及其制造方法
技术领域
本发明属于材料构件领域，涉及一种夹层玻璃，特别涉及一种应用在航空、建筑、汽车、机车等领域适于逃生或边部有刚度要求的门、窗或外墙中的夹层玻璃。
背景技术
夹层玻璃广泛上是指两边的透明材料与中间层胶片复合而成的玻璃深加工产品，中间层胶片以其特有的柔韧性和粘结力可以吸收外来的冲击能量，保证碎后玻璃的完整，故夹层玻璃是一种安全玻璃，广泛应用在航空、建筑、汽车、机车等领域。
但是在一些有安全要求同时又有逃生需求的场合，如飞机座舱、公共运输的车舱、特殊建筑等，在应用夹层玻璃的时候，胶片因其特有的粘弹性、延展性使其被破坏很困难，不能在短时间被敲碎或切割、爆破，故无法满足逃生的需求。
发明内容
针对上述问题，本发明的目的是设计并制造一种用于逃生或其他边部有刚度要求的安全玻璃，即提供一种边部结构一体化夹层玻璃。
本发明一种边部结构一体化夹层玻璃，包括两块或多块单片玻璃及夹设在相邻两块单片玻璃之间的胶片，胶片夹设在单片玻璃的中心区域，单片玻璃之间的边部区域为填充部，填充部宽度为20～50mm。
所述单片玻璃为可以为无机玻璃、有机玻璃或类似透明材料制成的板。
其中，分布在胶片两侧的单片玻璃材料可以相同或不同，厚度也可以相同或不同。
所述胶片材料为聚乙烯醇缩丁醛(PVB)、聚氨酯(PU)、乙烯与醋酸乙烯共聚物(EVA)、离子型聚合物(SGP)，或其类似物中的任何一种或几种的组合。
所述填充部由填充物填充固化得到，填充物优选与单片玻璃有较好粘结力的透明或不透明材料，可以为丙烯酸类聚合物、双酚A类聚合物、环氧类聚合物或其类似物。
所述边部结构一体化夹层玻璃，外形可为平面、弧形、双曲面或其它形状。
对于平面的夹层玻璃，所述填充物为液体或片状粘结材料。
所述边部结构一体化夹层玻璃，为多层夹层玻璃，其中多层胶片的材料可以相同或不同，厚度也可以相同或不同；多层填充部的填充材料可以相同或不同，厚度也可以相同或不同；同一层中胶片的厚度与填充部的厚度相等。
本发明另一目的是提供所述边部结构一体化夹层玻璃的制造方法。
该结构一体化夹层玻璃的制造方法，包括以下步骤：对胶片进行裁减预留所述填充部的位置，将胶片置于单片玻璃之间的中心区域合片，在合片玻璃的边部间隙位置填充与胶片等厚的片材，进气压釜或热压罐热压；去除片材后，通过湿法灌浆、真空移入、紫外固化等方法将填充物填充到合片玻璃的边部间隙中，封边后固化后得到边部结构一体化的夹层玻璃。
其中，所述填充间隙的片材可以是聚乙烯、聚丙烯、聚四氟乙烯等与单片玻璃、胶片不粘结或较难粘结的物质。
采取以上设计，本发明玻璃整体仍是夹层玻璃，仅在边部区域填充固化后有一定刚性的物质，使夹层玻璃边部的结构不同于中间区域，提高边部胶片层的刚度，使边部玻璃各层的力学性能近似、粘结力提高，外力可以较为容易从最外面一层传递到内层，并且边部各层较容易被破坏或与整体分离，可应用于航空、建筑、汽车、机车等领域有逃生或其它边部有刚度要求的门、窗或外墙中。
附图说明：
图1为本发明单层边部结构一体化夹层玻璃结构示意图。
图2为本发明多层边部结构一体化夹层玻璃结构示意图。
具体实施方式：
本发明是设计并制造一种用于逃生或其它边部有刚度要求的安全玻璃，即边部结构一体化的夹层玻璃。本发明的设计思路是将夹层玻璃的边部预留出来，填充一种固化后有一定刚性的物质，填充物与透明材料之间有较强的粘结力，使夹层玻璃边部的“玻璃/填充物/玻璃”成为一体，且各层的力学性能近似、粘结力提高；该种形式的夹层玻璃，内、外层的透明材料为完整的，但中间层的边部和中心区域使用的材料不同，当从外部向边部施力时，外力可以较容易从边部的外/内层传递到内/外层，使边部各层较容易被破坏，从而使夹层玻璃脱落。逃生的时候，可通过敲击或事先安放爆炸切割装备使夹层玻璃边部与中心区域分离。
本发明设计的边部结构一体化的夹层玻璃结构(局部)参见图1。图1显示了单层夹层玻璃的方式，其包括位于两侧的单片玻璃1和2，夹设于两单片玻璃之间中心区域的胶片3，以及固设于两单片玻璃之间边部区域的填充部4，边部区域宽度在20～50mm之间。其中：
单片玻璃1和2可以选择无机玻璃、有机玻璃等。两侧单片玻璃的材料可以相同或不同，因此本发明的夹层玻璃可以为无机、有机或无机-有机复合的夹层玻璃。无机玻璃本身的刚度较高，但是一种脆性材料，直接敲击就可破碎；有机玻璃有一定韧性，夹层玻璃的厚度在8mm以上常规敲击、撞击等方法不易破碎，可采用热切割的方法使玻璃边部与中间区域分开。
中间层胶片3可以选择聚乙烯醇缩丁醛(PVB)、聚氨酯(PU)、乙烯与醋酸乙烯共聚物(EVA)、离子型聚合物(SGP)等材料制成。
中间层边部填充部4是由填充物填充固化形成，填充物优选与单片玻璃有较好粘结力的透明材料，可以为丙烯酸类聚合物、双酚A类聚合物、环氧类等聚合物。边部填充物也可不透明，但选择与两侧单片玻璃相容性、粘结性好的物质，填充物固化后的力学性能可参考有机玻璃的相关要求。
本发明边部结构一体化的夹层玻璃外形可为平面、弧形、双曲面或其它形状。
夹层玻璃的制造方法可参考传统常规方法进行。但为了留出边部添加填充物的位置，应先对胶片进行裁减。将胶片3置于两侧单片玻璃1和2之间的中心对称位置进行合片，合片进气压釜或热压罐前，需在边部间隙位置填充与胶片等厚的片材，该片材与单片玻璃、胶片不粘，热压后可以取出。填充间隙的片材可以是聚乙烯、聚丙烯、聚四氟乙烯等较难粘结的物质。
移走边部片材，填充物可以通过湿法灌浆、真空移入等方法填充到边部，封边后固化。依据填充物的聚合机理或粘结要求，固化方式可以选择热固化、紫外固化、二次进釜热压等。对于平面的夹层玻璃，填充物除为液体外，也可以选择一定刚性的片状粘结材料。
本发明边部结构一体化的夹层玻璃的另一实施方式为，夹层玻璃结构可以是多层。参见图2所示，是在图1方式的基础上，增加了一层胶片3’、一层单片玻璃5以及在单片玻璃2和5之间边部的填充部4’。多层夹层玻璃方式中，每一单片玻璃1、2或5材料可以相同或不同，厚度也可以相同或不同；每层胶片3或3’材料可以相同或不同，厚度也可以相同或不同；填充部4或4’的材料可以相同或不同，厚度也可以相同或不同；但是：同一层中胶片3的厚度与填充部4的厚度相等，胶片3’的厚度与填充部4’的厚度相等；在宽度尺寸上，每一单片玻璃等宽，每一胶片3或3’宽度可以相等或不等，对应的每一填充部4或4’的宽度也可以相等或不等，在夹层玻璃被破坏时，多层结构的破坏点应位于填充部4或4’重叠部分从而使多层玻璃边部与中间区域分开。
依据图2示意的方式，夹层玻璃还可制成更多层，可按应用环境的需要设计，在此不再一一赘述。在选择中间层材料的时候，要考虑层合工艺的兼容及不同材料界面相容性，推荐选用聚氨酯胶片。
以下通过实施例进一步说明本发明。
实施例一：
1、聚氨酯胶片(厚度0.63mm)通过样板切裁好后，与有机玻璃(两片尺寸均为500mm×200mm×2～2.5mm)合片，使层合玻璃边部均匀预留宽20～40mm左右间隙；
2、边部间隙部位使用与胶片同厚、后期可移走的片材聚丙烯隔离，将有机层合玻璃预抽0.5～1小时，然后进气压釜或热压罐，按照常规工艺热压(真空度、-0.1Mpa、压力1.0～1.2Mpa、温度80～100℃)成有机夹层玻璃；
3、配制填充液：以甲基丙烯酸甲酯为主体，依次添加0.05％(重量)左右的自由基引发剂过氧化苯甲酰、13％(重量)的丙烯酸酯，搅拌下逐步升温到80±2℃，反应0.5～1小时后冷却至室温；
4、将填充液进行排泡处理，然后灌注到步骤2准备的有机夹层玻璃的边部间隙中，用聚四氟乙烯条封口后，进烘箱热固化，温度50±5℃，时间4～8小时，自然冷却到室温。得到本例边部结构一体化的夹层玻璃。
效果检测：
用刀片或其他坚硬工具在边部一体化夹层玻璃表面刻深度大于1mm的划痕，划痕的位置选择在填充物区域的中部、长度延伸到边部。对准划痕，垂直与划痕方向用力向两侧外撇，玻璃沿着划痕位置断开。
实施例二：
与实施例1相同的方法制造边部结构一体化的夹层玻璃，其中：
使用PVB或EVA作为胶片，两侧使用3mm无机玻璃作为单片玻璃，使用聚四氟乙烯膜包覆的胶片作为片材，进气压釜或热压罐复合成无机夹层玻璃，参数可直接选用常规PVB、EVA胶片的层合工艺。
采用湿法灌浆的方法，使用环氧树脂作为填充液灌注在无机夹层玻璃边部间隙中，封边后二次进气压釜或热压罐，升温到80～120℃，时间2～6小时，缓慢冷却到室温。得到本例边部结构一体化的夹层玻璃。
效果检测：
用刀片或其他坚硬工具在边部一体化夹层玻璃表面刻深度大于1mm的划痕，划痕的位置选择在填充物区域的中部、长度延伸到边部。对准划痕，垂直与划痕方向用力向两侧外撇，玻璃沿着划痕位置断开。
实施例三：
与实施例1相同的方法制造边部结构一体化的夹层玻璃，其中：
使用与实施例1相同的胶片、单片玻璃和片材，层合玻璃边部均匀预留间隙宽度在50mm左右；
采用湿法灌浆的方法，将丙烯酸紫外固化胶灌注在玻璃边部，封边后用紫外灯室温照射1～5分钟，随后可置于阳光下暴晒2～5小时，促使紫外胶完全固化。得到本例边部结构一体化的夹层玻璃。
效果检测：
用刀片或其他坚硬工具在边部一体化夹层玻璃表面刻深度大于1mm的划痕，划痕的位置选择在填充物区域的中部、长度延伸到边部。对准划痕，垂直与划痕方向用力向两侧外撇，玻璃沿着划痕位置断开。
实施例四：
1、玻璃结构：3mm有机玻璃/0.63mm聚氨酯胶片/3mm有机玻璃/0.63mm聚氨酯胶片/2mm无机玻璃，尺寸：300mm×300mm。其中，无机玻璃在外层。
2、聚氨酯胶片裁剪成200mm×200mm。此外，0.63mm的片材裁剪成宽度为50mm的长条，该片材包覆在聚四氟乙烯薄膜中。将裁剪好的胶片及包覆的片材按照本实施例中第1部分的结构层合好。其中，包覆片材放置在边部。
3、将层合玻璃进气压釜热压，参数：真空度-0.1Mpa、压力1.0～1.2Mpa、温度80～100℃。
4、取出包覆片材，按照实施例1中第3、4部分的方法制备填充物，得到本例边部结构一体化的夹层玻璃。
效果检测：
多层结构的玻璃总体厚度达到9.26mm，普通切割较难破坏玻璃。在距玻璃周圈边部25mm位置放置切割、爆炸锁，采用热切割和火药爆炸方式，周边25mm的方框与内部250mm的方框分离。

Claims (7)

1.边部结构一体化夹层玻璃的制造方法，所述夹层玻璃包括两块或多块单片玻璃及夹设在相邻两块单片玻璃之间的胶片，胶片夹设在单片玻璃的中心区域，单片玻璃之间的边部区域为填充部，填充部宽度为20～50mm；该制造方法包括以下步骤：对胶片进行裁减预留所述填充部的位置，将胶片置于单片玻璃之间的中心区域合片，在合片玻璃的边部间隙位置填充与胶片等厚的片材，进气压釜或热压罐热压；去除片材后，通过湿法灌浆、真空移入或紫外固化方法将填充物填充到合片玻璃的边部间隙中，封边后固化后得到边部结构一体化的夹层玻璃；
所述胶片材料为聚乙烯醇缩丁醛PVB、聚氨酯PU、乙烯与醋酸乙烯共聚物EVA和离子型聚合物SGP中的一种或几种；所述填充物为与单片玻璃有较好粘结力的透明或不透明材料丙烯酸类聚合物、双酚A类聚合物或环氧类聚合物。
2.如权利要求1所述边部结构一体化夹层玻璃的制造方法，其特征在于，所述填充间隙的片材是聚乙烯、聚丙烯或聚四氟乙烯与单片玻璃、胶片不粘结或较难粘结的材料。
3.如权利要求1所述的边部结构一体化夹层玻璃的制造方法，其特征在于，所述单片玻璃为无机玻璃、有机玻璃或类似透明材料制成的板。
4.如权利要求3所述的边部结构一体化夹层玻璃的制造方法，其特征在于，分布在胶片两侧的单片玻璃材料相同或不同，单片玻璃厚度相同或不同。
5.如权利要求1所述的边部结构一体化夹层玻璃的制造方法，其特征在于，所述夹层玻璃外形为平面、弧形或双曲面。
6.如权利要求5所述的边部结构一体化夹层玻璃的制造方法，其特征在于，对于平面的夹层玻璃，所述填充物为液体或片状粘结材料。
7.如权利要求1至6任一所述的边部结构一体化夹层玻璃的制造方法，其特征在于，所述夹层玻璃为多层夹层玻璃，其中多层胶片的材料相同或不同，厚度相同或不同；多层填充部的填充材料相同或不同，厚度相同或不同；同一层中胶片的厚度与填充部的厚度相等。
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