CN111452457B - 一种抗冲击高强防弹玻璃及其制备方法 - Google Patents

一种抗冲击高强防弹玻璃及其制备方法 Download PDF

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CN111452457B
CN111452457B CN202010340084.9A CN202010340084A CN111452457B CN 111452457 B CN111452457 B CN 111452457B CN 202010340084 A CN202010340084 A CN 202010340084A CN 111452457 B CN111452457 B CN 111452457B
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glass
semi
temperature
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glass substrate
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CN111452457A (zh
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吴从真
肖坚伟
陈杰
郑耿标
陈惜英
廖克生
林俊明
徐敏
王庆林
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Wujiang Golden Glass Technologies Ltd
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Abstract

本发明公开了一种抗冲击高强防弹玻璃的制备方法，包括：S1.清洗半钢化玻璃基片并风干；S2.按照半钢化玻璃基片、PVB胶片的叠合顺序进行叠合；S3.将叠合好的玻璃组合置于辊压上进行预压；S4.将预压后的玻璃组合送进高压釜进行蒸压，得到半成品玻璃基片夹层组合；S5.按照半成品玻璃基片夹层组合、PU膜和PC板的叠合顺序进行叠合，得到组合材料；S6.将叠片好后的组合材料装入真空袋进行封边处理；S7.将组合材料在温度为110‑120℃、压力为1.1‑1.25Mpa的条件下蒸压4‑6小时，得到防弹玻璃。本发明还公开了由该方法制备的防弹玻璃。本发明制备的防弹玻璃，整体自重可减轻20％‑30％左右，同时抗冲击性、防弹性能保持不变。

Description

一种抗冲击高强防弹玻璃及其制备方法
技术领域
本发明涉及防弹玻璃技术领域，具体涉及一种抗冲击高强防弹玻璃及其制备方法。
背景技术
近几年来，全球范围内的恐怖袭击活动时有发生，炸弹爆炸袭击所造成的破坏范围较大，不但对室外的人群构成严重的生命威胁，而且给在附近室内的人们造成极大的伤害和损失。据安全专家分析及有关资料显示：在炸弹爆炸的恐怖袭击事件中，有75％的伤害直接与建筑物玻璃的散落和碎片飞溅有关，因此，建筑物玻璃的散落和碎片飞溅是造成对人们伤害的主要原因。
目前，现有的防弹玻璃的制备工艺通常采取两次预压和蒸压过程，其中第二次预压与蒸压为分步进行，预压采用辊压法或真空袋法。这种工艺不仅较为复杂，而且无法通过辊压法生产曲面防弹玻璃。如公开号为CN105034544A的中国专利(公开日为2015年11月11日)公开了一种防弹玻璃的制备方法，它包括原料准备、夹层玻璃制作(包含预压)、合片、预压、压蒸成型的步骤。
另外，为提高玻璃的防弹性能，传统上一般采用增加玻璃厚度及夹层层数的方式来增强玻璃的防弹性能，但是由此带来了玻璃组合构件总厚度太厚及重量过重等弊端，对安装、使用带了很大的不便，相应的增加了生产成本及使用成本。
发明内容
本发明要解决的技术问题是提供一种抗冲击高强防弹玻璃的制备方法，该方法简化了现有的防弹玻璃的制备工艺，可解决曲面防弹玻璃不能用辊压法生产的难题；并且由该方法制备的防弹玻璃，在提高玻璃的抗冲击、抗穿透能力的同时，有效的减少了防弹玻璃的重量和厚度，降低了成本，整体自重可减轻20％-30％左右。
为了解决上述技术问题，本发明提供了如下所述的技术方案：
本发明第一方面提供了一种抗冲击高强防弹玻璃的制备方法，包括以下步骤：
S1.清洗：提供半钢化玻璃基片，清除表面的油脂和灰尘，并风干；
S2.第一次合片：按照半钢化玻璃基片、聚乙烯醇缩丁醛(PVB)胶片的叠合顺序，在温度为20±3℃、相对湿度为23％±5％的环境下进行叠合，得到玻璃组合；
S3.预压：将叠合好的玻璃组合置于辊压上进行预压，预压时前辊温度为60～180℃，后辊温度为150～240℃，辊压速度为0.3～2.4m/min，辊压压力为0.4～1.0Mpa；
S4.第一次蒸压成型：将预压后的玻璃组合送进高压釜进行蒸压，在温度为110～130℃、压力为1.2～1.3Mpa的条件下蒸压4～6小时，得到半成品玻璃基片夹层组合；
S5.第二次合片：检查半成品玻璃基片夹层组合的产品质量，确认合格后，按照半成品玻璃基片夹层组合、聚氨基甲酸酯(PU)膜和聚碳酸酯(PC)板的叠合顺序，在温度为20±3℃、相对湿度为23％±5％的环境下进行叠合，得到组合材料；
S6.抽真空处理：将叠片好后的组合材料进行包边并固定好，装入真空袋进行封边处理；
S7.第二次蒸压成型：将真空处理好的组合材料送进蒸压釜，使真空袋的抽气阀与蒸压釜内的吸气阀门相连接并抽真空，控制真空袋内呈负压；然后在温度为110-120℃、压力为1.1-1.25Mpa的条件下蒸压4-6小时，得到所述防弹玻璃。
本发明步骤S1中，清洗玻璃基片时，应根据玻璃厚度调整盘刷距离，清除玻璃表面的油脂、灰尘以控制夹层玻璃粘结力，玻璃清洗后须完全风干。玻璃清洗输出时应即时检查清洁度，不干净应重新清洗。
进一步地，步骤S1中，所述半钢化玻璃基片是由玻璃原片经过物理钢化工艺处理后得到的，其表面应力控制在24-69Mpa内。表面应力控制在在这个范围内，在使玻璃基片强度得到增强的，可以降低玻璃基片的自爆率，从而使玻璃质量保持稳定。
进一步地，所述玻璃原片应选用优质的原材料玻璃原片，先加工成预定规格，再清洗并烘干，烘干时的温度优选为55-90℃。
本发明步骤S2和S5中，在叠合过程中，应四边对齐，不能有叠差，玻璃及PVB胶片间不能有污染物存在。
进一步地，步骤S2和S5中，优选地在温度为22℃、湿度为20-27％的环境下进行叠合。
本发明步骤S3中，预压时应根据产品规格调整辊压距离，保证辊压距离应比玻璃厚度少2-4mm。进一步地，预压时，前辊温度为70～170℃，后辊温度为160～230℃，辊压速度为0.5～2.3m/min，辊压压力为0.6～0.9Mpa。优选地，辊压后玻璃表面温度为65-75℃。
进一步地，步骤S3中，玻璃组合经辊压后，若边部出现白色不透明的气泡，应在玻璃未冷却之前将增塑剂涂在出现气泡的玻璃边缘，等液体渗入后再送进高压釜进行蒸压。其中，所使用的夹层玻璃增塑剂优选地与PVB胶片品牌一致。
本发明步骤S6中，对真空袋进行封边处理后，应检查真空袋是否漏气。
进一步地，步骤S7中，控制蒸压釜内真空袋的负压为-0.8Mpa～-1.0Mpa。通过抽真空处理，使得无机夹层玻璃组合与PC板通过PU膜牢牢地粘合。
进一步地，步骤S7中，蒸压釜内升温与升压要同时进行，升温速率控制在1.5～3℃/min。
进一步地，步骤S7中，蒸压完成后，等温度降到45℃以下开始放压，在压力完全放完及温度降到室温后方可打开高压釜门。
本发明第二方面提供了由第一方面所述的方法制备得到的抗冲击高强防弹玻璃，所述防弹玻璃包括：
由多块半钢化玻璃基片与PVB胶片叠层组合形成的主承受力层；
作为防弹玻璃外层背面的PC板；以及
作为中间层组合所述主承受力层与所述PC板的PU膜。
进一步地，所述防弹玻璃中，半钢化玻璃基片的厚度为4～12mm，PVB胶片的厚度为0.38～2.28mm，PU膜的厚度为0.635～2.54mm，PC板的厚度为2～3mm。
与现有技术相比，本发明的有益效果在于：
1.本发明的防弹玻璃的制备工艺，第二次预压和蒸压为在高压釜一次成型，缩短了二次成型的时间、提高了效率；玻璃预热、预压、排气较充分，玻璃与PU膜、PC板贴合紧密，产品质量较佳，成品率较高，不易产生气泡(尤其是PU膜、PC板的角部气泡)、脱胶及PC板裂纹问题，且耐热性好。并且按照本发明S5-S7的步骤，可解决曲面防弹玻璃不能用辊压法生产的难题。
2.本发明以物理钢化工艺加工的半钢化度玻璃基片为主承力层，辅以高韧性、高抗穿透能力的PVB胶片组合玻璃基片，强化了玻璃的抗穿透性；同时以具有高抗冲击性的聚碳酸酯(PC板)作为外层背面，并以PU膜为中间层组合PC板，在提高玻璃的抗冲击、抗穿透能力的同时，能有效的减少防弹玻璃的重量和厚度，从而降低成本。该防弹玻璃在抗冲击性、防弹性能等指标保持不变的同时，整体自重可减轻20％-30％左右。
3.本发明的防弹玻璃，通过组合不同层数的玻璃基片，可达到适合各种场合的应用。具有强度高、抗冲击、重量轻及防紫外线等特点，具有优越的防弹性能。
附图说明
图1是本发明实施例1的防弹玻璃的结构示意图；
图2是本发明实施例2-3的防弹玻璃的结构示意图；
其中：1、半钢化玻璃基片；2、PVB胶片；3、PU膜；4、PC板。
具体实施方式
下面结合附图和具体实施例对本发明作进一步说明，以使本领域的技术人员可以更好地理解本发明并能予以实施，但所举实施例不作为对本发明的限定。
实施例1
1、平板玻璃基片处理：
选择玻璃原片，清洗并烘干后，通过物理钢化的方法提高其表面强度，得到半钢化玻璃基片，控制其表面应力在24-69Mpa。接着，清除半钢化玻璃基片表面的油脂和灰尘，并风干。
2、第一次合片、预压及蒸压成型：
保证合片室卫生和PVB胶片干净，然后按照半钢化玻璃基片、PVB胶片、半钢化玻璃基片的的叠合顺序，在温度为20±3℃、相对湿度为23％±5％的环境下进行叠合，得到玻璃组合。在叠合过程中，应四边对齐，不能有叠差。玻璃及PVB胶片间不能有污染物存在。
将叠合好的玻璃组合置于辊压上进行预压，根据产品规格调整辊压距离(应比玻璃厚度少2-4mm)，设置前辊温度为120℃，后辊温度为200℃，压力0.8Mpa。辊压速度参数为2.0m/min，辊压后玻璃表面温度约70℃。
将预压后的玻璃组合材料送进高压釜进行蒸压，在120℃的温度条件下1.2Mpa的压力条件下蒸压5小时，得到半成品玻璃基片夹层组合。
3、第二次合片、抽真空及蒸压成型
在合片室内，按照半成品玻璃基片夹层组合、PU膜和背板PC板的叠合顺序，在温度为20±3℃，相对湿度为23％±5％的环境内进行叠合，得到最终组合材料。
将上述最终组合材料进行包边，用胶纸固定好，装入真空袋进行封边处理，并检查真空袋是否漏气。
将上述封边后的真空袋送进蒸压釜，使真空袋的抽气阀与蒸压釜内的吸气阀门相连接并进行抽真空，控制真空袋内的负压在-0.8Mpa～-1.0Mpa。然后升温升压，升温速度控制在1.5～3℃/分钟，在120℃、1.2Mpa的温度压力条件下蒸压5小时，等温度降到45℃以下开始放压，在压力完全放完及温度降到室温后方可打开蒸压釜门，即可得到防弹玻璃。
本实施例得到的防弹玻璃，其结构如附图1所示，总厚为17.41mm。
实施例2
实施例2与实施例1的制备工艺相同，区别在于实施例2的玻璃结构为：玻璃基片/PVB胶片/玻璃基片/PVB胶片/玻璃基片/PU膜/PC板，总厚度为28.55mm。
实施例3
实施例2与实施例1的制备工艺相同，区别在于实施例2的玻璃结构为：玻璃基片/PVB胶片/玻璃基片/PVB胶片/玻璃基片/PU膜/PC板，总厚度为33.19mm。
以上所述实施例仅是为充分说明本发明而所举的较佳的实施例，本发明的保护范围不限于此。本技术领域的技术人员在本发明基础上所作的等同替代或变换，均在本发明的保护范围之内。本发明的保护范围以权利要求书为准。

Claims (10)

1.一种抗冲击高强防弹玻璃的制备方法，其特征在于，包括以下步骤：
S1.清洗：提供半钢化玻璃基片，清除表面的油脂和灰尘，并风干；
S2.第一次合片：按照半钢化玻璃基片、PVB胶片的叠合顺序，在温度为20±3℃、相对湿度为23％±5％的环境下进行叠合，得到玻璃组合；
S3.预压：将叠合好的玻璃组合置于辊压上进行预压，预压时前辊温度为60～180℃，后辊温度为150～240℃，辊压速度为0.3～2.4m/min，辊压压力为0.4～1.0Mpa；
S4.第一次蒸压成型：将预压后的玻璃组合送进高压釜进行蒸压，在温度为110～130℃、压力为1.2～1.3Mpa的条件下蒸压4～6小时，得到半成品玻璃基片夹层组合；
S5.第二次合片：检查半成品玻璃基片夹层组合的产品质量，确认合格后，按照半成品玻璃基片夹层组合、PU膜和PC板的叠合顺序，在温度为20±3℃、相对湿度为23％±5％的环境下进行叠合，得到组合材料；
S6.抽真空处理：将叠片好后的组合材料进行包边并固定好，装入真空袋进行封边处理；
S7.第二次蒸压成型：将真空处理好的组合材料送进蒸压釜，使真空袋的抽气阀与蒸压釜内的吸气阀门相连接并抽真空，控制真空袋内呈负压；然后在温度为110-120℃、压力为1.1-1.25Mpa的条件下蒸压4-6小时，得到所述防弹玻璃。
2.根据权利要求1所述的一种抗冲击高强防弹玻璃的制备方法，其特征在于，步骤S1中，所述半钢化玻璃基片是由玻璃原片经过物理钢化工艺处理后得到的，其表面应力控制在24-69Mpa内。
3.根据权利要求2所述的一种抗冲击高强防弹玻璃的制备方法，其特征在于，所述玻璃原片先加工成预定规格，再清洗并烘干，烘干时的温度为55-90℃。
4.根据权利要求1所述的一种抗冲击高强防弹玻璃的制备方法，其特征在于，步骤S2和S5中，在温度为22℃、湿度为20-27％的环境下进行叠合。
5.根据权利要求1所述的一种抗冲击高强防弹玻璃的制备方法，其特征在于，步骤S3中，预压时，前辊温度为70～170℃，后辊温度为160～230℃，辊压速度为0.5～2.3m/min，辊压压力为0.6～0.9Mpa。
6.根据权利要求1所述的一种抗冲击高强防弹玻璃的制备方法，其特征在于，步骤S3中，玻璃组合经辊压后，若边部出现白色不透明的气泡，应在玻璃未冷却之前将增塑剂涂在出现气泡的玻璃边缘，等液体渗入后再送进高压釜进行蒸压。
7.根据权利要求1所述的一种抗冲击高强防弹玻璃的制备方法，其特征在于，步骤S7中，控制蒸压釜内真空袋的负压为-0.8Mpa～-1.0Mpa。
8.根据权利要求1所述的一种抗冲击高强防弹玻璃的制备方法，其特征在于，步骤S7中，蒸压釜内升温与升压要同时进行，升温速率控制在1.5～3℃/min。
9.根据权利要求1-8任一项所述的方法制备得到的抗冲击高强防弹玻璃，其特征在于，所述防弹玻璃包括：
由多块半钢化玻璃基片与PVB胶片叠层组合形成的主承受力层；
作为防弹玻璃外层背面的PC板；以及
作为中间层组合所述主承受力层与所述PC板的PU膜。
10.根据权利要求9所述的抗冲击高强防弹玻璃，其特征在于，所述防弹玻璃中，半钢化玻璃基片的厚度为4～12mm，PVB胶片的厚度为0.38～2.28mm，PU膜的厚度为0.635～2.54mm，PC板的厚度为2～3mm。
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