CN113844126A - 一种车用防弹玻璃的制作方法及该防弹玻璃 - Google Patents

一种车用防弹玻璃的制作方法及该防弹玻璃 Download PDF

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CN113844126A
CN113844126A CN202111135994.4A CN202111135994A CN113844126A CN 113844126 A CN113844126 A CN 113844126A CN 202111135994 A CN202111135994 A CN 202111135994A CN 113844126 A CN113844126 A CN 113844126A
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bulletproof
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周琳琳
王凤磊
续芯如
赵晓伟
戚淑梅
孙玟
贾羽娜
何明曦
闫丽华
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Qinhuangdao Glass Industry Research And Design Institute Co ltd
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Abstract

本发明公开了一种车用防弹玻璃的制作方法及该防弹玻璃，包括叠加合片步骤、排气步骤和粘合步骤。本发明的制作方法将叠加合片后的玻璃放入真空袋，然后使用抽真空的方式排各层玻璃间的空气，并一直维持玻璃处于真空袋中的真空状态下置于高压釜中升温加压。由于排气后至升温加压前，玻璃一直处于真空袋的真空环境下，可防止空气进入各层玻璃间，因此用本发明方法制作得到的防弹玻璃内基本没有气泡，使得防弹玻璃的成品率、透光性、防弹性能都得以提高。

Description

一种车用防弹玻璃的制作方法及该防弹玻璃
技术领域
本发明涉及特种玻璃的制作方法技术领域，特别是涉及一种车用防弹玻璃的制作方法，及该方法制作出的防弹玻璃。
背景技术
国内车用防弹玻璃需要满足对53式7.62mm普通弹(钢心)有效射击不穿透的防弹要求。防弹玻璃一般采用两层普通钢化玻璃夹一片PVB胶片的“奥利奥饼干”结构，也有使用三层普通钢化玻璃夹两层PVB胶片的“三明治”结构，还有的采用两层钢化玻璃夹玻璃纤维片和PVB胶片的结构。
无论是“奥利奥饼干”结构，还是“三明治”结构的防弹玻璃普遍采用的制作方法是：先将普通钢化玻璃和胶片(还有玻璃纤维片)按顺序叠加合片，得到玻璃复合体，然后用辊压机对合片后的玻璃(即玻璃复合体)施加3-6MPa的压力以排除各层间的空气，最后把玻璃复合体装入高压釜中升温加压，使玻璃和胶片粘结形成防弹玻璃。
按《GJB3030-97装甲车辆用防弹玻璃规范》对防弹玻璃防弹级别的规定，即：在同一种枪型、弹型和同一个距离的情况下，试样经三次射击后，在没有弹头或弹片穿透试样时，根据试样背部飞溅物的不同情况，对防弹级别作出如下规定：A级，测试卡上有飞溅物，飞溅物没有穿透测试卡；B级，试样背部有飞溅物溅射，但测试卡上没有飞溅物；C级，试样背部没有飞溅物溅射，背部玻璃表面光滑，基本平整，没有大于3mm的凸起。从目前的制作方法可以看出，在辊压机排气后至高压釜升温加压前玻璃复合体处于常压环境，空气会进入玻璃层间，因此用这种方法制作出的防弹玻璃内部气泡较多，影响视线，且上述方法制作的防弹玻璃防弹级别基本为A级或B级，级别较低。不仅如此，辊压机对玻璃施加的压力高达3-6MPa，容易压裂玻璃，导致该方法制得的防弹玻璃成品率较低。
此外，按以上方法制作得到的防弹玻璃的厚度一般是42mm，重量为110kg/m2。若要进一步提高防弹玻璃的防弹级别，通常采用的方式为增加钢化玻璃的厚度。这就使得防弹玻璃的整体厚度也相应增加。厚度增加的防弹玻璃，重量也会增加，用在汽车上会增加车身自重，使得汽车提速慢、车速低，载重量(如载弹量)降低。
发明内容
本发明的目的是针对现有技术中存在的技术缺陷，第一方面，提供一种可减少防弹玻璃中气泡的车用防弹玻璃制作方法，包括叠加合片步骤、排气步骤和粘合步骤，所述排气步骤是将叠加合片步骤得到的玻璃复合体放入真空袋中抽至袋内真空度为0.08-0.1MPa，排气后将真空袋连同袋内的玻璃复合体一起再进行粘合步骤。
所述粘合步骤具体为：将真空袋及其内部的玻璃复合体放置于高压釜中先升温保持一段时间，再在此温度下增压并保持一段时间至将玻璃复合体粘合成一体，然后先保持压力降温至室温，再降压至常压，最后从真空袋内取出粘合后的玻璃复合体即为制作完成的防弹玻璃。
高压釜先升温至120-140℃保持1-4h，再在此温度下增压至1.0-1.2MPa并保持1-4h。
所述叠加合片步骤具体为：将形状相同、尺寸相同的玻璃片和胶片依次叠放，玻璃片与胶片完全重叠，形成玻璃复合体。
所述玻璃复合体依次包括：PC板层(7)、第三胶片层、超白玻璃层(5)、第二胶片层、高硼硅玻璃层(3)、第一胶片层和高铝化学钢化玻璃层(1)。
所述第一胶片层、第二胶片层和第三胶片层分别为SGP胶片层(2)、PVB胶片层(4)和PU胶片层(6)。
所述PU胶片层的厚度为0.625-2.50mm；SGP胶片层的厚度为0.89-2.28mm和PVB胶片层的厚度为0.76-2.28mm。
所述超白玻璃层、高硼硅玻璃层和高铝化学钢化玻璃层的厚度为5-12mm。
第二方面，本发明提供上述方法制作得到的车用防弹玻璃，每0.1m2内不存在密集的直径不大于0.5mm的气泡，直径为0.5mm-1.0mm之间的气泡不超过4个，直径为1.0mm-2.0mm之间的气泡不超过2个。
其整体厚度为34-40.3mm，其重量为84-100kg/m2；优选的，其防弹级别为《GJB3030-97装甲车辆用防弹玻璃规范》中的C级。
与现有技术相比，本发明的有益效果是：
本发明的制作方法将叠加合片后的玻璃复合体放入真空袋，然后使用抽真空的方式排除各层间的空气，并一直维持玻璃复合体处于真空状态下置于高压釜中升温加压。由于排气后至升温加压前，玻璃复合体一直处于真空袋内的真空环境下，可防止空气进入各层间，并且真空袋内的真空度为0.08-0.1MPa，比辊压机施加在玻璃上的压力低得多，不会对玻璃造成损伤；因此用本发明方法制作得到的防弹玻璃内基本没有气泡，使得成品率、透光性、防弹性能都得以提高，均能达到C级。
此外，本发明在综合权衡不同玻璃的硬度、抗冲击性、热膨胀系数等性能后，最终确定制作的防弹玻璃选用硬度高的高铝化学钢化玻璃、高硼硅玻璃替代在迎弹面方向的普通钢化玻璃。为了保证防弹玻璃的透光性，在背弹面方向用超白玻璃替代普通钢化玻璃；还在背弹面侧的最外层设置聚碳酸酯板，以防止玻璃被子弹射穿产生玻璃碎片二次伤人。本发明方法制作出的防弹玻璃降低了防弹玻璃整体的厚度，从而在保证其防弹性能符合国军标GJB3030-97的前提下，甚至提高了防弹等级的基础上，降低了防弹玻璃的重量，进而降低了使用防弹玻璃汽车的自重，使得汽车的提速加快、能达到更高的车速、载重量也得以提高。
附图说明
图1所示为本发明方法制作得到的车用防弹玻璃的剖面示意图，
图中：1：高铝化学钢化玻璃层，2：SGP胶片层，3：高硼硅玻璃层，4：PVB胶片层，5：超白玻璃层，6：PU胶片层，7：PC板层。
具体实施方式
本发明提供一种车用防弹玻璃的制作方法，包括以下步骤：
S1)、将PC板、PU胶片、超白玻璃、PVB胶片、SGP胶片均切割成相同的尺寸(如420mm×420mm的大小)；
定制与超白玻璃相同尺寸的高硼硅玻璃和高铝玻璃，并对高铝玻璃进行化学钢化。化学钢化是将玻璃置于400℃左右熔融的碱盐(简称“熔盐”)中，使玻璃表层中半径较小的离子与熔盐中半径较大的离子交换，如玻璃中的锂离子与熔盐中的钾离子或钠离子交换，又如玻璃中的钠离子与熔盐中的钾离子进行交换。交换后玻璃表层中碱离子体积的变化在玻璃两表面形成嵌挤压应力，内部形成张应力，从而达到提高玻璃强度的效果。由于化学钢化玻璃表面的压应力较小，与其平衡的内部张应力不大，因此化学钢化玻璃的内部张应力层达到破坏时不会像物理钢化玻璃那样碎成小片，避免玻璃碎片二次伤人。化学钢化玻璃强度高、热稳定性好、表面不变形、可做适当切裁处理、无自爆现象。
S2)、清洗超白玻璃、高硼硅玻璃和高铝化学钢化玻璃。
S3)、叠加合片步骤：将PC板置于最底层，在PC板上方平铺一层PU胶片，在PU胶片上方放置一片清洗后的超白玻璃；在超白玻璃上方平铺一层PVB胶片，在PVB胶片上方放置一片清洗后的高硼硅玻璃；在高硼硅玻璃上方平铺一片SGP胶片，在SGP胶片上方放置一片清洗后的高铝化学钢化玻璃；完成叠加合片，得到玻璃复合体。
S4)、排气步骤：将玻璃复合体的四角用胶带固定，将固定好的玻璃复合体放入真空袋中抽至真空度为0.08-0.1MPa，真空袋可耐200℃高温。
S5)、粘合步骤：将真空袋连通其中的玻璃复合体一同放入高压釜中，关好釜门，对釜内抽真空至真空度为0.08-0.1MPa，并保持1-4小时，以尽可能多地排除玻璃复合体各层间的空气。
S6)、粘合步骤：打开高压釜的电加热开关，将温度升到120-140℃，保持这个温度1-4个小时，此时升温可使各胶片层充分熔化，以提高后续对玻璃的粘结力。
S7)、粘合步骤：步骤S6结束后高压釜在此温度下开始加压，加压至压力达到1.0-1.2MPa，保持此压力温度1-4个小时，使玻璃层与胶片层充分粘结成一个整体。
S8)、粘合步骤：步骤S7结束后关掉电加热，继续保持压力在1.0-1.2MPa范围内降温至室温；保持压力降温是为了避免在降温的过程中，玻璃复合体内部进入气泡。
S9)、粘合步骤：降至室温后，释放高压釜内的压力，当压力降到0.1MPa时，打开高压釜，从真空袋内取出制作完成的防弹玻璃。
按上述方法制作得到的车用防弹玻璃，结构如图1所示，从下至上(以背弹面方向为下，以迎弹面方向为上)依次包括：PC板层7、PU胶片层6、超白玻璃层5、PVB胶片层4、高硼硅玻璃层3、SGP胶片层2和高铝化学钢化玻璃层1。防弹玻璃整体的厚度为34-40.3mm，重量为84-100kg/m2，透光率不低于73％，防弹级别能达到《GJB3030-97装甲车辆用防弹玻璃规范》中规定的C级，每0.1m2内不存在密集(气泡间距小于50mm为密集)的直径不大于0.5mm的气泡，直径为0.5mm-1.0mm的气泡不超过4个，直径为1.0mm-2.0mm的气泡不超过2个。防弹玻璃中的胶片层、玻璃层过薄，防不住子弹的冲击，子弹会穿透，防弹性能无法保证；过厚，会使防弹玻璃整体厚度增加，玻璃重量也增加，从而增加使用该玻璃汽车的自重。经过多方面的探索和权衡，制作得到的防弹玻璃中：
PC板即聚碳酸酯板(英文：Polycarbonate，缩写为PC)是指分子链中含有碳酸酯基的高分子聚合物，根据酯基的结构可分为脂肪族、芳香族、脂肪族-芳香族等多种类型。PC板层7的厚度为3-6mm，优选6㎜，过薄可能会被子弹击穿，过厚会增加防弹玻璃整体的重量。PC板为有机透明板材，刚硬且有较好的弹性和韧性，抗冲击性能优异、尺寸稳定性高、电绝缘性和耐热性良好、无毒性、使用温度范围宽、透光能力良好，透光率接近90％，且较玻璃单位面积具有较轻的重量。PC板在遭受较大的冲击或较剧烈的震动时，仅仅出现裂纹，而不会导致粉碎和飞溅，用于防弹玻璃背弹面方向的第一层，可防止玻璃被子弹击穿产生的碎片对车内人员的二次伤害。
PU即聚氨酯(英语：Polyurethane，缩写为PU)是指主链中含有氨基甲酸酯特征单元的一类高分子。PU胶片层6的厚度为0.625-2.50mm，优选0.625-1.88mm，更优选1.25㎜。PU胶片是一种透明高粘性薄膜，用于粘接有机板材和玻璃。由于PC板是高分子有机材料，其与超白玻璃之间只能用PU胶片粘结。
超白玻璃层5的厚度为5-12mm，优选8㎜。超白玻璃具有较高的透光率，透光率≥91％，置于背弹面方向的第一个玻璃层，能够保证防弹玻璃整体的透光率。
PVB即聚乙烯醇缩丁醛(英文：Polyvinyl Butyral，缩写为PVB)，是一种高分子材料。PVB胶片为半透明膜片，对玻璃有较强的粘结力，具有透明、耐高温、耐低温、耐潮湿、机械强度高等特性。PVB胶片能吸收子弹冲击的能量，不产生破碎片。该胶片在具有较高安全性能的同时，还有优异的隔音、光控、保温、隔热、防震等性能。PVB胶片层4的厚度为0.76-2.28mm，优选1.52㎜。
高硼硅玻璃层3的厚度为5-12mm，优选8㎜。这种玻璃具有较高的强度、抗冲击能力和抗震性，且具有一定的韧性，能够阻挡子弹，发挥防弹效果。
SGP(Sentry Glas Plus)胶片无色透明，不易变色，通透性极佳，具有优良的韧性(用撕裂强度表征)，高硬度、高强度、高透明度、高耐久性等优点。SGP胶片的撕裂强度是普通PVB的5倍，硬度是普通PVB的100倍，用作防弹玻璃中的胶片，其撕裂强度和硬度可在一定程度上阻挡子弹，发挥一定的防弹效果；其韧性也能吸收弹头的部分动能。SGP胶片层2的厚度为0.89-2.28mm，优选1.52mm。
高铝化学钢化玻璃层1的厚度为5-12mm，优选8㎜。子弹射出会携带较大的冲击力和温度，由于高铝化学钢化玻璃的热膨胀系数低，与子弹碰撞时，受子弹携带热量影响发生的热膨胀形变小，仅是与子弹接触的地方有弹孔，玻璃的整体结构不会被破坏。又由于高铝化学钢化玻璃具有较好的机械强度，即硬度(指基体平均硬度)和表面硬度(指化学钢化后表层某一个深度范围的硬度)都比普通钢化玻璃高，对子弹冲击力的缓冲作用强，玻璃的应力可使弹头变形或破坏弹头，减慢弹头的速度，阻挡弹头，降低子弹对玻璃内部结构造成的伤害，使得玻璃的防弹性能提高，因此置于防弹玻璃迎弹面方向的第一层。
以下结合具体实施例，更具体地说明本发明的内容，并对本发明作进一步阐述，但这些实施例绝非对本发明进行限制。
实施例
按上述制作方法制作实施例1-6的车用防弹玻璃，由下至上(由背弹面侧至迎弹面侧，作为车用防弹玻璃时，即是由车内侧至车外侧)依次包括PC板层、PU胶片层、超白玻璃层、PVB胶片层、高硼硅玻璃层、SGP胶片层和高铝化学钢化玻璃层，各参数和性能见表1。
按《GJB3030-97装甲车辆用防弹玻璃规范》中的方法测试实施例1-6的防弹玻璃，结果显示实施例1-6的防弹玻璃的防弹级别均能达到C级。表1的结果表明本发明方法制作得到的防弹玻璃整体厚度在34-40.3mm之间，重量不超过100kg/m2。
可见，本发明方法制作得到的防弹玻璃降低了整体的厚度，在提高了防弹等级的基础上，还降低了防弹玻璃的重量。
表1实施例防弹玻璃的各参数和性能
Figure BDA0003282051550000061
比较例
按实施例1的方法制作得到比较例1-6的防弹玻璃，仅是玻璃或胶片的种类发生了改变，或制作方法的某个参数发生了改变，具体见表2。表2中按防弹玻璃由下至上(由背弹面侧至迎弹面侧，作为车用防弹玻璃时，即是由车内侧至车外侧)的结构顺序列出各层玻璃或胶片的种类。
表2的结果显示，比较例1-比较例5的防弹玻璃在整体厚度、重量和透光率等方面能与实施例1-6相当，但防弹性能均不符合《GJB3030-97装甲车辆用防弹玻璃规范》中对防弹玻璃的防弹要求，如第一发子弹就可穿透比较例2的防弹玻璃(在玻璃上出现孔洞或者可以透光的裂缝)，第二发子弹就可穿透比较例1、比较例4和比较例6的防弹玻璃，第三发子弹可穿透比较例3和比较例5的防弹玻璃。
表2比较例防弹玻璃的各参数和性能
Figure BDA0003282051550000071
以上所述仅是本发明的优选实施方式，应当指出的是，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的内容。

Claims (10)

1.一种车用防弹玻璃的制作方法，包括叠加合片步骤、排气步骤和粘合步骤，其特征在于，所述排气步骤是将叠加合片步骤得到的玻璃复合体放入真空袋中抽至袋内真空度为0.08-0.1MPa，排气后将真空袋连同袋内的玻璃复合体一起再进行粘合步骤。
2.根据权利要求1所述制作方法，其特征在于，所述粘合步骤具体为：将真空袋及其内部的玻璃复合体放置于高压釜中先升温保持一段时间，再在此温度下增压并保持一段时间至将玻璃复合体粘合成一体，然后先保持压力降温至室温，再降压至常压，最后从真空袋内取出粘合后的玻璃复合体即为制作完成的防弹玻璃。
3.根据权利要求2所述制作方法，其特征在于，高压釜先升温至120-140℃保持1-4h，再在此温度下增压至1.0-1.2MPa并保持1-4h。
4.根据权利要求1-3任一所述制作方法，其特征在于，所述叠加合片步骤具体为：将形状相同、尺寸相同的玻璃片和胶片依次叠放，玻璃片与胶片完全重叠，形成玻璃复合体。
5.根据权利要求4所述制作方法，其特征在于，所述玻璃复合体依次包括：PC板层(7)、第三胶片层、超白玻璃层(5)、第二胶片层、高硼硅玻璃层(3)、第一胶片层和高铝化学钢化玻璃层(1)。
6.权利要求5所述制作方法，其特征在于，所述第一胶片层、第二胶片层和第三胶片层分别为SGP胶片层(2)、PVB胶片层(4)和PU胶片层(6)。
7.根据权利要求6所述制作方法，其特征在于，所述PU胶片层的厚度为0.625-2.50mm；SGP胶片层的厚度为0.89-2.28mm和PVB胶片层的厚度为0.76-2.28mm。
8.根据权利要求5-7任一所述制作方法，其特征在于，所述超白玻璃层、高硼硅玻璃层和高铝化学钢化玻璃层的厚度为5-12mm。
9.权利要求1-8任一所述方法制作得到的车用防弹玻璃，其特征在于，每0.1m2内不存在密集的直径不大于0.5mm的气泡，直径为0.5mm-1.0mm之间的气泡不超过4个，直径为1.0mm-2.0mm之间的气泡不超过2个。
10.根据权利要求9所述车用防弹玻璃，其特征在于，其整体厚度为34-40.3mm，其重量为84-100kg/m2；优选的，其防弹级别为《GJB3030-97装甲车辆用防弹玻璃规范》中的C级。
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CN114347593A (zh) * 2022-01-17 2022-04-15 绍兴市戎马汽车零部件有限公司 一种集成热固性透明树脂的防弹玻璃
CN116217076A (zh) * 2022-12-24 2023-06-06 云南呈达企业集团有限公司 一种高强度防弹防爆玻璃的制备方法
CN117162609A (zh) * 2023-08-17 2023-12-05 上海同百建设科技股份有限公司 一种耐候电磁屏蔽防火多层复合透明防弹材料及工艺
CN117183489A (zh) * 2023-08-17 2023-12-08 上海同百建设科技股份有限公司 一种耐候远红外吸收多层复合多功能透明防弹材料及工艺

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