CN110561859A - 一种生产胶合玻璃的方法及胶合玻璃 - Google Patents
一种生产胶合玻璃的方法及胶合玻璃 Download PDFInfo
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Abstract
本发明涉及一种生产胶合玻璃的方法及胶合玻璃,属于玻璃制造技术领域。所述生产胶合玻璃的方法包括如下步骤:(1)在合片室里进行合片,合片是将胶合膜铺设在第一透明基材上,再将第二透明基材铺装在胶合膜上,得到的合片置入真空袋内,或者在真空袋内将胶合膜铺设在第一透明基材上,再将第二透明基材铺装在胶合膜上;(2)将装有合片的真空袋置入反应釜内,于反应釜内将真空袋抽真空至负压,同时将反应釜内升温至100~140℃且加压至9~14kg/cm2,保温保压0.5~4h,再降温至常温,降压至常压,即得到胶合玻璃。本发明的生产胶合玻璃的方法节省了操作步骤和时间,生产效率高,产品质量好,效果稳定。
Description
技术领域
本发明属于玻璃制造技术领域,特别涉及一种生产胶合玻璃的方法及胶合玻璃。
背景技术
安全玻璃是一种经剧烈振动或撞击不破碎,即使破碎也不易伤人的玻璃。胶合玻璃是安全玻璃的一种,在汽车和建筑领域得到广泛的应用。
目前,生产胶合玻璃的方法一般是先将两片玻璃通过PVB胶粘合在一起,形成合片;其后,将合片进行加热预压处理;其后,将加热预压处理后的合片用C型夹具进行加压,再将加压后的合片转移至高压釜中加热成型,成型后的合片再经修边,即得到胶合玻璃。在进行加热预压的过程中,加热升温能够使PVB胶片融化从而粘合两片玻璃,预压能够将两片玻璃中间的气泡排出。但是,加热预压处理仅能够较好地去除平面玻璃基材之间的气泡,而无法将曲面玻璃基材之间的气泡排尽,最终得到的胶合玻璃中会仍有较多成品存在夹杂明显气泡的现象,十分影响产品的质量,降低了企业的竞争力。
发明内容
本发明为了解决上述背景技术中的技术问题,提供一种生产胶合玻璃的方法,其能够克服目前加热预压处理仅能够较好地去除平面玻璃基材之间的气泡,而无法将曲面玻璃基材之间的气泡排尽,得到的胶合玻璃中仍有较多成品存在夹杂明显气泡的现象的技术问题。
本发明解决上述技术问题的技术方案如下:一种生产胶合玻璃的方法,其包括步骤:
(1)准备胶合膜、第一透明基材和第二透明基材,其后在合片室里进行合片,所述合片是将胶合膜铺设在第一透明基材上,再将第二透明基材铺装在胶合膜上,得到的合片置入真空袋内,或者在真空袋内将胶合膜铺设在第一透明基材上,再将第二透明基材铺装在胶合膜上;
(2)将步骤(1)得到的装有合片的真空袋置入反应釜内,将真空袋抽真空至-0.1~-0.2kg/cm2,同时将反应釜内升温至100~140℃且加压至9~14kg/cm2,保温保压0.5~4h,再降温至常温,降压至常压,即得到胶合玻璃。
本发明的有益效果是:
(1)本发明方法中装有合片的真空袋直接在反应釜中进行抽真空处理,减少了设备投入,节省了操作步骤和时间,大大提升了生产效率;
(2)本发明方法的合片在反应釜中反应时,合片不仅由于抽真空会受到负压的作用效果,还由于反应釜增加压缩空气会受到加压的效果,在负压和正压的双重作用效果下第一透明基材和第二透明基材自然地张合在一起,未有气泡产生;
(3)本发明方法中,同批次生产的胶合玻璃均符合GB15763.3-2009《建筑用安全玻璃第3部分:夹层玻璃》的外观要求,成品质量较高,效果稳定。
可以理解的是,上述保温是指反应釜内保持温度100~140℃;上述保压是指保持真空袋内压力为-0.1~-0.2kg/cm2和反应釜内压力为9~14kg/cm2。
在上述技术方案的基础上,本发明还可以做如下改进。
进一步,步骤(1)中,所述第一透明基材和第二透明基材均为平面玻璃基材或曲面玻璃基材。
采用上述进一步方案的有益效果是本发明制造的胶合玻璃时,原材料无论是平面玻璃基材还是曲面玻璃基材都具有较好的外观,未有气泡产生,且质量稳定。
进一步,步骤(1)中,所述胶合膜为PVC胶合膜、EVA胶合膜、PVB胶合膜或SGP胶合膜中的至少一种。
可以理解的是,所述PVC胶合膜是指聚氯乙烯胶合膜;所述EVA胶合膜是指聚乙烯醋酸乙酯胶合膜;所述PVB胶合膜是指聚乙烯醇缩丁醛胶合膜;所述SGP胶合膜是指乙烯共聚甲基丙烯酸胶合膜。
还可以理解的是,本发明的中的胶合膜并不限定于上述PVC胶合膜、EVA胶合膜、PVB胶合膜或SGP胶合膜,以具体可以实现固定第一透明基材和第二透明基材功能之间的固定为准。
进一步,步骤(1)中,所述第一透明基材和所述第二透明基材均为普通玻璃基材、超白玻璃基材、减反射玻璃基材、钢化玻璃基材、半钢化玻璃基材和有机玻璃基材中的至少一种。
进一步,步骤(1)中,所述合片室为无尘合片室,内部的温度为20~25℃,相对湿度为20~40%。
采用上述进一步方案的有益效果是在通过限定合片的制作环境能够为终产物胶合玻璃的质量奠定基础。
进一步,步骤(1)中,单个所述真空袋中置入多份合片,多份所述合片重叠设置。
采用上述进一步方案的有益效果是本发明能够一次性快速处理多份合片,提高了生产速度。
进一步,步骤(2)中,将所述反应釜内升温至125~135℃且加压至11~12kg/cm2。
采用上述进一步方案的有益效果是在11~12kg/cm2的正压环境下能够减少胶合玻璃的成型时间,提高生产效率。
本发明还提供一种由上述生产胶合玻璃的方法生产得到的胶合玻璃。
本发明的有益效果是:本发明胶合玻璃的外观透明无气泡;胶合玻璃的力学性能佳,其耐热性、耐湿性、霰弹、冲击和水煮均符合GB15763.3-2009《建筑用安全玻璃第3部分:夹层玻璃》的要求。
进一步,所述胶合玻璃包括至少一胶合膜、至少一第一透明基材和至少一第二透明基材,所述胶合膜夹设在所述第一透明基材和所述第二透明基材之间。
可以理解的是,本发明的胶合玻璃可以为胶合膜夹设在第一透明基材和第二透明基材之间这样的3层的结构,胶合玻璃也可以为超过3层的结构,例如所述胶合玻璃包括第一胶合膜、第二胶合膜、第一透明基材、第二透明基材和第三透明基材,第一胶合膜设置于第一透明基材表面上,第二透明基材设置在第一胶合膜远离第一透明基材的表面上,第二胶合膜设置在第二透明基材远离第一胶合膜的表面上,第三透明基材设置在第二胶合膜远离第二透明基材的表面上。
进一步,所述第一透明基材和所述第二透明基材的厚度均为3~20mm,所述胶合膜的厚度为0.38~3.8mm。
采用上述进一步方案的有益效果是既可以节省材料,又能保证产品所需的技术要求和性能。
附图说明
图1为本发明生产的胶合玻璃结构示意图。图中,2为第一透明基材,4为第二透明基材,6为胶合膜。
具体实施方式
下面通过具体实施方式和对比例对本发明做进一步的详细描述,但是本领域技术人员将会理解,下列实施方式仅用于说明本发明,而不应视为限制本发明的范围。实施方式中未注明具体条件者,按照常规条件或制造商建议的条件进行。所用设备、试剂或仪器未注明生产厂商者,均为可以通过市售购买获得的常规产品。
实施方式1
本方式提供的一种生产胶合玻璃的方法,其包括步骤:
(1)准备PVB胶合膜、经清洗的第一曲面普通玻璃基材和经清洗的第二曲面普通玻璃基材,其后在合片室里进行合片,所述合片是将PVB胶合膜铺设在第一曲面普通玻璃基材上,再将第二曲面普通玻璃基材铺装在PVB胶合膜上,得到1份合片置入硅胶真空袋内,其中,所述无尘合片室内的温度为23℃,相对湿度为30%;
(2)将步骤(1)得到的装有合片的硅胶真空袋用摆渡车送入反应釜内,将硅胶真空袋上预置的硅胶管插入与真空泵连接的快速接头,进行抽真空前的准备工作,其后关上反应釜门,于所述反应釜内将所述硅胶真空袋抽真空至-0.1kg/cm2,同时将所述反应釜内升温至125℃且加压至11kg/cm2,保温保压2h,再降温至常温,降压至常压,即得到胶合玻璃。
本方式还提供一种由上述生产胶合玻璃的方法生产得到的胶合玻璃,如图1所示,所述胶合玻璃包括PVB胶合膜6、第一曲面普通玻璃基材2和第二曲面普通玻璃基材4,所述PVB胶合膜6夹设在所述第一曲面普通玻璃基材2和所述第二曲面普通玻璃基材4之间,所述第一曲面普通玻璃基材2和所述第二曲面普通玻璃基材4的厚度为3mm,所述PVB胶合膜6的厚度为0.38mm。
实施方式2
本方式提供的一种生产胶合玻璃的方法,其包括步骤:
(1)准备PVC胶合膜、经清洗的第一平面半钢化玻璃基材和经清洗的第二平面半钢化玻璃基材,其后在合片室里进行合片,所述合片是在硅胶真空袋内将PVC胶合膜铺设在第一平面半钢化玻璃基材上,再将第二平面半钢化玻璃基材铺装在PVC胶合膜上,其中,所述无尘合片室内的温度为20℃,相对湿度为40%;
(2)将步骤(1)得到的装有合片的硅胶真空袋用摆渡车送入反应釜内,将硅胶真空袋上预置的硅胶管插入与真空泵连接的快速接头,进行抽真空前的准备工作,其后关上反应釜门,于所述反应釜内将所述硅胶真空袋抽真空至-0.2kg/cm2,同时将所述反应釜内升温至135℃且加压至9kg/cm2,保温保压0.5h,再降温至常温,降压至常压,即得到胶合玻璃。
本方式还提供一种上述生产胶合玻璃的方法生产得到的胶合玻璃,如图1所示,所述胶合玻璃包括PVC胶合膜6、第一平面半钢化玻璃基材2和第二平面半钢化玻璃基材4,所述PVC胶合膜6夹设在所述第一平面半钢化玻璃基材2和所述第二平面半钢化玻璃基材4之间,所述第一平面半钢化玻璃基材2和所述第二平面半钢化玻璃基材4的厚度为20mm,所述PVC胶合膜6的厚度为3.8mm。
实施方式3
本方式提供的一种生产胶合玻璃的方法,其包括步骤:
(1)准备EVA胶合膜、经清洗的第一曲面有机玻璃基材和经清洗的第二曲面有机玻璃基材,其后在合片室里进行合片,所述合片是将EVA胶合膜铺设在第一曲面有机玻璃基材上,再将第二曲面有机玻璃基材铺装在EVA胶合膜上,得到5份合片重叠置入硅胶真空袋内,其中,所述无尘合片室内的温度为25℃,相对湿度为20%;
(2)将步骤(1)得到的装有合片的硅胶真空袋用摆渡车送入反应釜内,将硅胶真空袋上预置的硅胶管插入与真空泵连接的快速接头,进行抽真空前的准备工作,其后关上反应釜门,于所述反应釜内将所述硅胶真空袋抽真空至-0.15kg/cm2并保压,同时将所述反应釜内升温至105℃且加压至13kg/cm2,保温保压3.8h,再降温至常温,降压至常压,即得到胶合玻璃。
本方式还提供一种上述生产胶合玻璃的方法生产得到的胶合玻璃,如图1所示,所述胶合玻璃包括EVA胶合膜6、第一曲面有机玻璃基材2和第二曲面有机玻璃基材4,所述EVA胶合膜6夹设在所述第一曲面有机玻璃基材2和所述第二曲面有机玻璃基材4之间,所述第一曲面有机玻璃基材2和所述第二曲面有机玻璃基材4的厚度为6mm,所述EVA胶合膜6的厚度为2.28mm。
对比方式1
本方式提供一种生产胶合玻璃的方法,本方式与实施方式1的区别在于,将步骤(1)得到的装有合片的硅胶真空袋抽真空至-0.15kg/cm2,并对其加热至135℃,同时保持气压恒定,加热预压10mi n,其后将加热预压处理后的合片用C型夹具进行加压,再将加压后的合片转移至反应釜中加热成型,成型后的合片再经修边,即得到胶合玻璃。
本方式还提供一种上述生产胶合玻璃的方法生产得到的胶合玻璃,其与实施方式1相同。
将实施方式1至实施方式3、对比方式1得到的胶合玻璃按照GB15763.3-2009《建筑用安全玻璃第3部分:夹层玻璃》进行外观测试,实施方式1至实施方式3和对比方式1的测试结果如下表1:
表1
由表1显示,实施方式1至实施方式3生产得到的胶合玻璃中,几乎全部胶合玻璃的内部及边沿均无气泡,相比于对比方式1,对比方式1生产得到的胶合玻璃无法完全去除气泡,可知,实施方式1至实施方式3生产得到的胶合玻璃明显质量较好,且效果稳定。
为了更进一步研究本发明的耐热性,将实施方式1至实施方式3、对比方式1得到的胶合玻璃按照GB15763.3-2009《建筑用安全玻璃第3部分:夹层玻璃》进行耐热性测试,实施方式1至实施方式3和对比方式1的测试结果如下表2:
表2
由表2显示,实施方式1至实施方式3生产得到的胶合玻璃的耐热性均符合国家标准的要求。对比方式1生产得到的胶合玻璃不符合国家标准的要求,可知,实施方式1至实施方式3生产得到的胶合玻璃具有更好的耐热性。
本发明还将实施方式1至实施方式3得到的胶合玻璃按照GB15763.3-2009《建筑用安全玻璃第3部分:夹层玻璃》分别进行耐湿性、霰弹、冲击和水煮的测试,测试结果是实施方式1至实施方式3得到的胶合玻璃均符合上述几种测试的要求。
另外,本发明为了进一步研究合片在反应釜内进行抽真空和合片在反应釜外进行抽真空的区别,增设了下面的对比方式2。
对比方式2
本方式提供一种生产胶合玻璃的方法,本方式与实施方式1的区别在于,将步骤(1)得到的装有合片的硅胶真空袋抽真空至-0.1kg/cm2并密封,其后将装有合片的硅胶真空袋用摆渡车送入反应釜内,再将所述反应釜内升温至125℃且加压至11kg/cm2,保温保压2h,再降温至常温,降压至常压,即得到胶合玻璃。
本方式还提供一种上述生产胶合玻璃的方法生产得到的胶合玻璃,其与实施方式1相同。
将实施方式1至实施方式3、对比方式2得到的胶合玻璃按照GB15763.3-2009《建筑用安全玻璃第3部分:夹层玻璃》进行外观测试,实施方式1至实施方式3和对比方式1的测试结果如下表3:
表3
由表3显示,实施方式1至实施方式3生产得到的胶合玻璃中,几乎全部胶合玻璃的内部及边沿均无气泡,相比于对比方式2,对比方式2仅有3件生产得到的胶合玻璃的内部及边沿均无气泡,可知,实施方式1至实施方式3生产得到的胶合玻璃明显质量更好,且效果更稳定。
以上所述仅为本发明的较佳实施例,并不用以限制本发明,凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (10)
1.一种生产胶合玻璃的方法,其特征在于,包括如下步骤:
(1)准备胶合膜、第一透明基材和第二透明基材,其后在合片室里进行合片,所述合片是将胶合膜铺设在第一透明基材上,再将第二透明基材铺装在胶合膜上,得到的合片置入真空袋内,或者在真空袋内将胶合膜铺设在第一透明基材上,再将第二透明基材铺装在胶合膜上;
(2)将步骤(1)得到的装有合片的真空袋置入反应釜内,将真空袋抽真空至-0.1~-0.2kg/cm2,同时将反应釜内升温至100~140℃且加压至9~14kg/cm2,保温保压0.5~4h,再降温至常温,降压至常压,即得到胶合玻璃。
2.根据权利要求1所述的生产胶合玻璃的方法,其特征在于,步骤(1)中,所述第一透明基材和第二透明基材均为平面玻璃基材或曲面玻璃基材。
3.根据权利要求1所述的生产胶合玻璃的方法,其特征在于,步骤(1)中,所述胶合膜为PVC胶合膜、EVA胶合膜、PVB胶合膜和SGP胶合膜中的至少一种。
4.根据权利要求1所述的生产胶合玻璃的方法,其特征在于,步骤(1)中,所述第一透明基材和所述第二透明基材均为普通玻璃基材、超白玻璃基材、减反射玻璃基材、钢化玻璃基材、半钢化玻璃基材和有机玻璃基材中的至少一种。
5.根据权利要求1所述的生产胶合玻璃的方法,其特征在于,步骤(1)中,所述合片室为无尘合片室,内部的温度为20~25℃,相对湿度为20~40%。
6.根据权利要求1任一项所述的生产胶合玻璃的方法,其特征在于,步骤(1)中,单个所述真空袋中置入多份合片,多份所述合片重叠设置。
7.根据权利要求1所述的生产胶合玻璃的方法,其特征在于,步骤(2)中,将所述反应釜内升温至125~135℃且加压至11~12kg/cm2。
8.一种由如权利要求1至6任一项所述的生产胶合玻璃的方法生产得到的胶合玻璃。
9.根据权利要求8所述的胶合玻璃,其特征在于,所述胶合玻璃包括至少一胶合膜、至少一第一透明基材和至少一第二透明基材,所述胶合膜夹设在所述第一透明基材和所述第二透明基材之间。
10.根据权利要求9所述的胶合玻璃,其特征在于,所述第一透明基材和所述第二透明基材的厚度均为3~20mm,所述胶合膜的厚度为0.38~3.8mm。
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