EP4017726A1 - Method for making a laminated glazing - Google Patents

Method for making a laminated glazing

Info

Publication number
EP4017726A1
EP4017726A1 EP20764745.4A EP20764745A EP4017726A1 EP 4017726 A1 EP4017726 A1 EP 4017726A1 EP 20764745 A EP20764745 A EP 20764745A EP 4017726 A1 EP4017726 A1 EP 4017726A1
Authority
EP
European Patent Office
Prior art keywords
sheet
glass
major surface
spacer
interlayer structure
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP20764745.4A
Other languages
German (de)
French (fr)
Inventor
Neil Winstanley
Neil John Durbin
Tomasz TELEGA
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Pilkington Group Ltd
Original Assignee
Pilkington Group Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Pilkington Group Ltd filed Critical Pilkington Group Ltd
Publication of EP4017726A1 publication Critical patent/EP4017726A1/en
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a non-planar shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
    • B32B17/10036—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising two outer glass sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
    • B32B17/10036—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising two outer glass sheets
    • B32B17/10045—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising two outer glass sheets with at least one intermediate layer consisting of a glass sheet
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
    • B32B17/10082—Properties of the bulk of a glass sheet
    • B32B17/10091—Properties of the bulk of a glass sheet thermally hardened
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
    • B32B17/10082—Properties of the bulk of a glass sheet
    • B32B17/10119—Properties of the bulk of a glass sheet having a composition deviating from the basic composition of soda-lime glass, e.g. borosilicate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
    • B32B17/10128—Treatment of at least one glass sheet
    • B32B17/10137—Chemical strengthening
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10165—Functional features of the laminated safety glass or glazing
    • B32B17/10174—Coatings of a metallic or dielectric material on a constituent layer of glass or polymer
    • B32B17/1022—Metallic coatings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10165—Functional features of the laminated safety glass or glazing
    • B32B17/10293—Edge features, e.g. inserts or holes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/10559—Shape of the cross-section
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/10761—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing vinyl acetal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/1077—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/10788—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing ethylene vinylacetate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10807—Making laminated safety glass or glazing; Apparatus therefor
    • B32B17/10816—Making laminated safety glass or glazing; Apparatus therefor by pressing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10807—Making laminated safety glass or glazing; Apparatus therefor
    • B32B17/10899—Making laminated safety glass or glazing; Apparatus therefor by introducing interlayers of synthetic resin
    • B32B17/10935—Making laminated safety glass or glazing; Apparatus therefor by introducing interlayers of synthetic resin as a preformed layer, e.g. formed by extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/44—Number of layers variable across the laminate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/412—Transparent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/738—Thermoformability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars

Definitions

  • the present invention relates to a method for making a laminated glazing, in particular a light weight laminated glazing for use in a vehicle.
  • the window is the vehicle windscreen, but may be a vehicle side window, rear window or sunroof.
  • a vehicle side window may be referred to as a vehicle side light.
  • the vehicle has at least one, usually two, movable side windows, one on either side of the vehicle i.e. the passenger side and the driver side.
  • movable side windows there may be one or more fixed side windows, for example front or rear quarter lights.
  • a side window In the driver’s door there is usually a side window that is movable in a vertical direction by actuation of a suitable winder mechanism.
  • the winder mechanism may be manually or electrically operated and has at least one element in mechanical communication with the side window to move the side window within the vehicle aperture region defining the driver’s side window.
  • a vehicle side window may comprise a sheet of thermally toughened glass.
  • thermally toughened sheet of glass When such a thermally toughened sheet of glass is broken, the integrity of the vehicle side window is lost as the sheet of glass is broken into many small fragments.
  • the laminated side window may have a construction such that when the side window is fully closed, the sheet of glass facing the interior of the vehicle does not extend fully downwards to the winder mechanism. Instead the winder mechanism is only connected to a connector region that is part of the outer sheet of glass of the laminated glazing. Actuation of the winder mechanism still moves the inner sheet of glass at the same time as the outer sheet of glass because the outer sheet of glass is joined to the inner sheet of glass by the adhesive interlayer material (such as PVB). However, the winder mechanism is not in direct physical contact with the inner sheet of glass.
  • JPS58-199752A1 discloses a laminated glazing where a spacer is used in the production thereof. An intermediate fdm of polyvinyl butyral having external dimensions less than those of a first glass sheet is placed on the first glass sheet and a release type soft spacer is disposed in the marginal part at the peripheral edge of the first glass plates where there is no intermediate film.
  • a second glass plate is placed on the intermediate film and the spacer, after which a lamination process is used to join the first glass plate to the second glass plate by the intermediate film.
  • the spacer is removed following lamination and a moisture impermeable sealant is positioned in the void left between the first and second glass pates upon removal of the spacer. In such a process it may be difficult to remove the spacer because the lamination process may cause the first and second glass plates to essentially clamp the spacer therebetween.
  • a problem when the inner facing sheet of a laminated side window for a vehicle only covers the aperture portion of the door is that upon lamination, there may be uneven lamination stress with an increased risk of delamination and/or reduced optical quality in the aperture region.
  • the present invention aims to at least partially overcome these problems.
  • the present invention provides a method for making a laminated glazing comprising the steps: (i) providing a first sheet of glass having a first major surface and a second opposing major surface, an interlayer structure comprising at least a first sheet of adhesive interlayer material, a second sheet of glass having a first major surface and a second opposing major surface and a spacer having a first major surface and a second opposing major surface; (ii) positioning the interlayer structure, the spacer and the second sheet of glass on the second major surface of the first sheet of glass such that a first portion of the second major surface of the first sheet of glass is covered by at least a portion of the interlayer structure and a second portion of the second major surface of the first sheet of glass is not covered by the interlayer structure, the second sheet of glass is on the interlayer structure and the first major surface of the second sheet of glass faces the second major surface of the first sheet of glass and the spacer is on the second portion of the second major surface of the first sheet of glass and the second major surface of the space
  • a laminated glazing made using a method according to the first aspect of the present invention has at least two regions, a first region comprising in sequence the first sheet of glass, the first sheet of adhesive interlayer material and the second sheet of glass, and a second region that does not include the second sheet of glass and/or the first sheet of adhesive interlayer material as a part thereof.
  • the optical quality of the laminated glazing in the first region thereof is higher than making the same laminated glazing without using a spacer.
  • Optical quality may be assessed using methods known in the art, such as described in W02004/083835A1 or US5,694,479.
  • the spacer is in direct contact with the second portion of the second major surface of the first sheet of glass.
  • the first sheet of glass is laminated to the second sheet of glass via the interlayer structure by laminating at a temperature at least 5 °C higher than the softening temperature of the first sheet of adhesive interlayer material, preferably at least 10 °C higher than the softening temperature of the first sheet of adhesive interlayer material.
  • the first sheet of glass to the second sheet of glass via the interlayer structure is carried out at a temperature in the range 60 to 150 °C, preferably 90 to 140 °C.
  • laminating the first sheet of glass to the second sheet of glass via the interlayer structure is carried out at a pressure in the range 5 to 20 bar, preferably 5 to 16 bar.
  • the spacer covers the entire second portion of the second major surface of the first sheet of glass, although in a preferred embodiment the spacer is sufficiently spaced from the interlayer structure to allow de-airing of the unlaminated stack during step (iii).
  • Each of the second sheet of glass and the interlayer structure has a respective thickness.
  • spacer has a thickness that is substantially the same, or the same, as the combined thickness of the second sheet of glass and the interlayer structure.
  • the spacer has an outer periphery and the second portion of the second major surface of the first sheet of glass has an outer periphery.
  • the outer periphery of the spacer is alignable with at least part of the outer periphery of the second portion of the sheet of support material.
  • the spacer comprises a releasable adhesive on at least a portion of the first and/or second major surface thereof.
  • a releasable adhesive on the first and/or second major surface of the spacer it is possible to temporarily maintain the position of the spacer relative to the second portion of the second major surface of the first sheet of glass prior to and/or during and/or after step (iii).
  • the one or more intervening layers may have one or more opening therein, and an opening in each layer may be aligned with an opening in a successive layer such that a hole extends through successive layers and preferably opens onto the second major surface of the first sheet of glass.
  • the spacer may comprise a portion extending from the first major surface thereof to extend into the aligned openings when the spacer is on the interlayer structure, and preferably the portion extending from the first major surface of the spacer contacts the second major surface of the first sheet of glass when the spacer is positioned on the interlayer structure.
  • the interlayer structure comprises a second sheet of adhesive interlayer material and following step (ii), the second sheet of adhesive interlayer material is between the first sheet of glass and the first sheet of adhesive interlayer material and the first sheet of adhesive interlayer material is between the second sheet of glass and the second sheet of adhesive interlayer material.
  • the second sheet of adhesive interlayer material comprises polyvinyl butyral (PVB), acoustic modified PVB, polyurethane (PU) or a copolymer of ethylene such as ethylene vinyl acetate (EVA).
  • PVB polyvinyl butyral
  • PU polyurethane
  • EVA ethylene vinyl acetate
  • the second sheet of adhesive interlayer material has a thickness between 0.3mm and 2.3mm, more preferably between 0.3mm and 1.6mm, even more preferably between 0.3mm and 0.9mm.
  • the entire second portion of the second major surface of the first sheet of glass is covered by at least a portion of the second sheet of adhesive interlayer material, more preferably the entire second major surface of the first sheet of glass is covered by at least a portion of the second sheet of adhesive interlayer material.
  • the second sheet of adhesive interlayer material is coextensive with the second sheet of glass.
  • the interlayer structure comprises a first and second sheet of adhesive interlayer material
  • the second sheet of adhesive interlayer material has an opening therein and following step (vii) the spacer covers the opening in the second sheet of adhesive interlayer material.
  • the spacer is configured with a portion extending from the first major surface thereof and following step (vii) the portion extending from the first major surface of the spacer is positioned in the opening in the second sheet of adhesive interlayer material.
  • the portion extending from the first major surface of the spacer directly contacts the second major surface of the first sheet of glass.
  • the interlayer structure comprises a sheet of support material between the first sheet of adhesive interlayer material and a second sheet of adhesive interlayer material.
  • the second sheet of adhesive interlayer material comprises polyvinyl butyral (PVB), acoustic modified PVB, polyurethane (PU) or a copolymer of ethylene such as ethylene vinyl acetate (EVA).
  • PVB polyvinyl butyral
  • PU polyurethane
  • EVA ethylene vinyl acetate
  • the second sheet of adhesive interlayer material has a thickness between 0.3mm and 2.3mm, more preferably between 0.3mm and 1.6mm, even more preferably between 0.3mm and 0.9mm.
  • the second sheet of adhesive interlayer material is coextensive with the sheet of support material.
  • the second sheet of adhesive interlayer material is coextensive with the sheet of support material and the first sheet of glass.
  • the second sheet of adhesive interlayer material is coextensive with the sheet of support material and the first sheet of glass, and the first sheet of adhesive interlayer material is coextensive with second sheet of glass.
  • the sheet of sheet of support material has a higher rigidity than the first and/or second sheets of adhesive interlayer material.
  • the sheet of support material is more dimensionally stable than the first and/or second sheets of adhesive interlayer material.
  • the sheet of support material is stiffer than the first and/or second sheets of adhesive interlayer material.
  • the sheet of support material has a higher rigidity than the first and/or second sheets of adhesive interlayer material.
  • the rigidity of the sheet of support material and the first and/or second sheet of adhesive interlayer material may be determined prior to being incorporated into the laminated glazing. Standard methods in the art may be used to determine rigidity.
  • the sheet of support material is more dimensionally stable than the first and/or second sheets of adhesive interlayer material.
  • the dimensional stability of a material may be measured using a standard method, for example as defined in ASTM D1204 and may be carried out at one or more temperature between 50-150 °C. Dimensional stability may be determined prior to being incorporated into the laminated glazing.
  • the sheet of support material is stiffer than the first and/or second sheets of adhesive interlayer material. Stiffness may be determined by measuring the extent to which the sample under investigation deforms in response to an applied force. Relative stiffness between the sheet of support material and the first and/or second layer of adhesive interlayer material may be determined prior to being incorporated into the laminated glazing using standard methods known in the art.
  • the sheet of support material comprises a material having a Young’s modulus (often referred to as Modulus of Elasticity, E) between x GPa and y GPa, wherein x is 0.1, 0.2, 0.3, 0.4, 0.5, 1.0 or 1.5 andy is 10, 20, 30, 40, 50, 60, 70, 80, 90 or 100.
  • the sheet of support material comprises a material having a Young’s modulus (E) between 0.1 GPa and 100 GPa. Young’s modulus may be determined using standard methods known in the art.
  • the sheet of support material has a Young’s modulus between 0.1 GPa and 100 GPa.
  • Dynamic mechanical properties may be determined in accordance with a standard method such as ASTM D4065.
  • Young’s Modulus of an adhesive interlayer material such as polyvinyl butyral may be determined as a function of temperature and load duration or frequency.
  • the sheet of support material comprises a polyester.
  • the sheet of support material comprises polyethylene terephthalate (PET).
  • PET polyethylene terephthalate
  • the sheet of support material comprises a sheet of glass.
  • the sheet of support material comprises an ionoplast interlayer material such as SentryGlas®.
  • the sheet of support material is monolithic
  • the sheet of support material is multi-layered.
  • the sheet of support material comprises at least two layers (a first layer and a second layer) that are the same material or are of different materials.
  • the sheet of support material has a thickness between 20pm and 1000pm, more preferably between 50pm and 500pm.
  • the sheet of support material is thinner than the second sheet of glass and the second sheet of glass is thinner than the first sheet of glass.
  • the sheet of support material has a coating on at least a portion of a major surface thereof.
  • the coating on the major surface of the sheet of support material may cover the entire major surface of the sheet of support material and/or may be a solar control coating and may comprise one or more layer of silver.
  • a first portion of the sheet of support material is between the first and second sheets of adhesive interlayer material and a second portion of the sheet of support material is not between the first and second sheets of interlayer material such that the second portion of the sheet of support material comprises an exposed surface.
  • the spacer is in direct contact with the second portion of the sheet of support material.
  • the sheet of support material has an opening therein and the opening in the sheet of support material is covered by the spacer following step (ii).
  • the second sheet of adhesive interlayer material has an opening therein, and the opening in the second sheet of adhesive interlayer material is at least partially aligned with an opening in the sheet of support material.
  • the spacer comprises a portion extending from the first major surface thereof and the portion extending from the first major surface of the spacer at least partially extends into the opening in the sheet of support material following step (ii).
  • the portion extending from the first major surface of the spacer at least partially extends into the opening in the second sheet of adhesive interlayer material.
  • the portion extending from the first major surface of the spacer contacts the second major surface of the first sheet of glass following step (ii).
  • the interlayer structure is first positioned on the second major surface of the first sheet of glass, then the second sheet is glass positioned on the interlayer structure, and then the spacer is positioned on the second major surface of the first sheet of glass.
  • methods for making a laminated glazing comprising the steps: (a) providing a first sheet of glass having a first major surface and a second opposing major surface; (b) providing an interlayer structure, the interlayer structure comprising at least a first sheet of adhesive interlayer material; (c) positioning the interlayer structure on the second major surface of the first sheet of glass such that a first portion of the second major surface of the first sheet of glass is covered by at least a portion of the first sheet of adhesive interlayer material and a second portion of the second major surface of the first sheet of glass is not covered by the first sheet of adhesive interlayer material; (d) providing a second sheet of glass having a first major surface and a second opposing major surface; (e) positioning the second sheet of glass on the interlayer structure such that the first major surface of the second sheet of glass faces the second major surface of the first sheet of glass; (f) providing a spacer having a first major surface and a second opposing major surface; (g) positioning
  • the interlayer structure may be provided at any time prior to being positioned on the second major surface if the first sheet of glass.
  • the second sheet of glass may be provided at any time prior to being positioned on the interlayer structure.
  • the spacer may be provided at any time prior to being positioned on the second portion of the second major surface of the first sheet of glass.
  • the interlayer structure is first positioned on the second major surface of the first sheet of glass, then the spacer is positioned on the second major surface of the first sheet of glass, and then the second sheet of glass positioned on the interlayer structure.
  • methods for making a laminated glazing comprising the steps: (a) providing a first sheet of glass having a first major surface and a second opposing major surface; (b) providing an interlayer structure, the interlayer structure comprising at least a first sheet of adhesive interlayer material; (c) positioning the interlayer structure on the second major surface of the first sheet of glass such that a first portion of the second major surface of the first sheet of glass is covered by at least a portion of the first sheet of adhesive interlayer material and a second portion of the second major surface of the first sheet of glass is not covered by the first sheet of adhesive interlayer material; (d) providing a spacer having a first major surface and a second opposing major surface; (e) positioning the spacer on the second portion of the second major surface of the first sheet of glass; (f) providing a second sheet of glass having a first major surface and a second opposing major surface; (g) positioning the second sheet of glass on the interlayer structure such that the first major
  • the interlayer structure may be provided at any time prior to being positioned on the second major surface if the first sheet of glass.
  • the spacer may be provided at any time prior to being positioned on the second portion of the second major surface of the first sheet of glass.
  • the second sheet of glass may be provided at any time prior to being positioned on the interlayer structure.
  • the spacer is first positioned on the second major surface of the first sheet of glass, then the interlayer structure is positioned on the second major surface of sheet of glass, and then the second sheet of glass positioned on the interlayer structure.
  • methods for making a laminated glazing comprising the steps: (a) providing a first sheet of glass having a first major surface and a second opposing major surface; (b) providing a spacer having a first major surface and a second opposing major surface; (c) positioning the spacer on the second major surface of the first sheet of glass such that a first portion of the second major surface of the first sheet of glass is not covered by the spacer and a second portion of the second major surface of the first sheet of glass is covered by at least a portion of the spacer and the first major surface of the spacer faces the second major surface of the first sheet of glass; (d) providing an interlayer structure, the interlayer structure comprising at least a first sheet of adhesive interlayer material; (e) positioning the interlayer structure on the first portion of the second major surface of the first sheet of glass; (f) providing a second sheet of glass having a first major surface and a second opposing major surface; (g) positioning the second sheet of glass
  • the spacer may be provided at any time prior to being positioned on the second major surface of the first sheet of glass.
  • the interlayer structure may be provided at any time prior to being positioned on first portion of the second major surface of the first sheet of glass.
  • the second sheet of glass may be provided at any time prior to being positioned on the interlayer structure.
  • the interlayer structure comprises a sheet of support material between the first sheet of adhesive interlayer material and a second sheet of adhesive interlayer material
  • the spacer has a pattern in or on the first major surface of the spacer.
  • the pattern in or on the first major surface of the spacer is transferred to the sheet of support material and/or the second sheet of adhesive interlayer material. The pattern may be transferred by pressing the first major surface of the spacer having the pattern therein or thereon, against the sheet of support material during step (iii).
  • the spacer is configured to nest on or with the second portion of the second major surface of the first sheet of glass.
  • step (ii) and before step (iii) a first mould is provided for pressing against the second sheet of glass and/or the spacer during step (iii).
  • the first mould is used to cold form the second sheet of glass during step (iii).
  • the first mould has a shape substantially the same as a shape of the first sheet of glass.
  • the first mould is a sheet of glass.
  • the first mould When a first mould is used, the first mould is removed from the surface of the second sheet of glass and/or the spacer following step (iii).
  • a mould is provided for pressing against the first sheet of glass during step (iii).
  • the mould is used to press the interlayer structure against the second sheet of glass during step (iii).
  • the spacer comprises a plastic material.
  • the spacer comprises polyethylene terephthalate, polyethylene, polyvinyl chloride, polypropylene, polystyrene, polylactic acid, polycarbonate, acrylic, acrylonitrile butadiene styrene, nylon or polyoxymethylene.
  • the spacer comprises a rubber material.
  • the rubber may be a natural rubber or a synthetic rubber.
  • spacer comprises chlorosulfonated polyethylene (CSM), ethylene propylene diene monomer (EPDM), fluoroelastomers (FKM), polychloroprene (CR), silicone rubber (SiR) or styrene butadiene rubber (SBR).
  • CSM chlorosulfonated polyethylene
  • EPDM ethylene propylene diene monomer
  • FKM fluoroelastomers
  • CR polychloroprene
  • SiR silicone rubber
  • SBR styrene butadiene rubber
  • the first glass sheet prior to step (iii) has a curvature in at least one direction, and the second sheet of glass is flat, or substantially flat, or has less curvature than the first sheet of glass.
  • the laminated glazing has a curvature defined by the curvature of the first sheet of glass.
  • the second sheet of glass is cold formed to a curvature defined essentially by the curvature of the first sheet of glass.
  • a mould may be used to press against the second sheet of glass to cold form the second sheet of glass during step (iii).
  • the first sheet of adhesive interlayer material is coextensive with the first sheet of glass.
  • the first sheet of adhesive interlayer material comprises polyvinyl butyral (PVB), acoustic modified PVB, a copolymer of ethylene such as ethylene vinyl acetate (EVA), polyurethane (PU) or poly vinyl chloride (PVC).
  • PVB polyvinyl butyral
  • EVA ethylene vinyl acetate
  • PU polyurethane
  • PVC poly vinyl chloride
  • the first sheet of adhesive interlayer material has a thickness between 0.3mm and 2.3mm, more preferably between 0.3mm and 1.6mm, even more preferably between 0.3mm and 0.9mm.
  • the first sheet of glass has a thickness between 1.0mm and 10mm, more preferably between 1.4mm and 6.0mm, even more preferably between 1.4mm and 3.0mm.
  • the first sheet of glass is a coated sheet, there being a coating on the first and/or second major surface of the first sheet of glass.
  • the coating on the first and/or second major surface of the first sheet of glass may be a low emissivity coating or a solar control coating.
  • Such coatings are known in the art and may comprise one or more layer of silver.
  • the second sheet of glass is a coated sheet, there being a coating on the first and/or second major surface of the first sheet of glass.
  • the coating on the first and/or second major surface of the second sheet of glass may be a low emissivity coating or a solar control coating.
  • Such coatings are known in the art and may comprise one or more layer of silver.
  • the first sheet of glass is a sheet of float glass.
  • the first sheet of glass is a sheet of soda-lime-silicate glass.
  • the first sheet of glass has soda-lime-silicate glass composition comprising (by weight), Si0 2 69- 74 %; A1 2 0 3 0 - 3 %; Na 2 0 10 - 16 %; K 2 0 0 - 5 %; MgO 0 - 6 %; CaO 5 - 14 %; S03 0 - 2%.
  • the first sheet of glass has a soda-lime-silicate glass composition comprising (by weight), Si0 2 69 - 74 %; A1 2 0 3 0 - 3 %; Na 2 0 10 - 16 %; K 2 0 0 - 5 %; MgO 0 - 6 %; CaO 5 - 14 %; S03 0 - 2 % and Fe 2 0 3 0.005 - 2 %.
  • a soda-lime-silicate glass composition comprising (by weight), Si0 2 69 - 74 %; A1 2 0 3 0 - 3 %; Na 2 0 10 - 16 %; K 2 0 0 - 5 %; MgO 0 - 6 %; CaO 5 - 14 %; S03 0 - 2 % and Fe 2 0 3 0.005 - 2 %.
  • the first sheet of glass is a sheet of thermally toughened glass or thermally semi- toughened glass.
  • the first sheet of glass has a thickness between 1.3mm and 1.49mm and a surface compressive stress in at least a central region of the first major surface of the first sheet of glass sheet in the range of 18MPa to 23MPa.
  • the first sheet of glass has a thickness between 1.5mm and 1.69mm and a surface compressive stress in at least a central region of the first major surface of the first sheet of glass in the range of 23.1 MPa to 26MPa.
  • the first sheet of glass has a thickness between 1.7mm and 1.99mm and a surface compressive stress in at least a central region of the first major surface of the first sheet of glass in the range of 26.1 MPa to 30MPa.
  • the first sheet of glass has a thickness between 2.0mm and 2.19mm and a surface compressive stress in at least a central region of the first major surface of the first sheet of glass in the range of 30.1MPato 35MPa.
  • the first sheet of glass has a thickness between 2.2mm and 2.49mm and a surface compressive stress in at least a central region of the first major surface of the first sheet of glass in the range of 35.1MPato 45MPa.
  • the first sheet of glass has a thickness between 2.5mm and 2.7mm and a surface compressive stress in at least a central region of the first major surface of the first sheet of glass in the range of45.1MPato 65MPa.
  • the first sheet of glass has a thickness between 2.71mm and 6mm and a surface compressive stress in at least a central region of the first major surface of the first sheet of glass in the range of 65.1 MPa to 150MPa, more preferably in the range of 65.1 MPa to lOOMPa.
  • the thickness of the second sheet of glass is less than 1.0mm, preferably less than 0.8mm.
  • the thickness of the second sheet of glass is greater than 0.3mm.
  • the thickness of the second sheet of glass is between 0.3mm and 1.0mm.
  • the thickness of the second sheet of glass is between 0.3mm and 0.8mm.
  • the second sheet of glass has been chemically strengthened.
  • the second sheet of glass is an alkali aluminosilicate glass composition.
  • the second sheet of glass includes at least about 6wt% aluminium oxide.
  • the second sheet of glass has a composition comprising 66-72 mol. % S1O2, 1-4 mol. % AI2O3, 8-15 mol. % MgO, 1-8 mol. % CaO, 12-16 mol.% Na 2 0, preferably wherein MgO + CaO is between 12 and 17 mol. % and CaO/(MgO + CaO) is in the range 0.1 and 0.4.
  • the second sheet of glass has a composition comprising (by weight) 58% to 70% S1O2, 5% to 15% AI2O3, 12% to 18% Na 2 0, 0.1% to 5% K 2 0, 4% to 10% MgO and 0% to 1% CaO with the provisos that the sum of the AI2O3 and MgO exceeds 13%, that the sum of the amounts of AI2O3 plus MgO divided by the amount of K2O exceeds 3 and that the sum of the Na 2 0 plus K2O plus MgO exceeds 22%.
  • the second sheet of glass is chemically strengthened to have a surface compressive stress greater than 400MPa, preferably between 400MPa and 900MPa, more preferably between 400MPa and 700MPa, even more preferably between 450MPa and 675MPa.
  • the second sheet of glass is chemically strengthened to have a surface compressive stress of around 900MPa or less.
  • the second sheet of glass is chemically strengthened to have a depth of layer (DOL) between 10 pm and 60pm, more preferably between 25pm and 45pm, even more preferably between 30pm and 40pm.
  • DOL depth of layer
  • the spacer has a uniform thickness defined by the separation of the first and second major surfaces of the spacer.
  • the method according to the first aspect of the present invention is used to make a laminated vehicle window, in particular a laminated vehicle side window.
  • the present invention provides a vehicle having an aperture for a window, in particular a side window, wherein a laminated glazing made according to the first aspect of the present invention is movable or fixed within the aperture.
  • the laminated glazing made according to the first aspect of the present invention is configured such that the first and/or second sheet of glass comprises a respective first connection portion for connecting the laminated glazing to a mechanism for moving the laminated glazing, preferably in a vertical direction, and the laminated glazing is movable in the aperture in the vehicle by means of the mechanism connected to the first connection portion of the first or second sheet of glass.
  • the laminated glazing is vertically movable in the aperture.
  • the vehicle has an interior and the aperture has a periphery, wherein the laminated glazing is movable to a first position to close the aperture such that from the outside of the vehicle, the interior of the vehicle is not accessible via the aperture, and when the laminated glazing is in the first position there is a portion of the laminated glazing not facing the aperture and a portion of the second major surface of the first sheet of glass is not directly facing the first major surface of the second sheet of glass.
  • Figure 1 is a schematic plan view of a vehicle side window made in accordance with the first aspect of the present invention
  • Figure 2 is a schematic cross-sectional representation of the vehicle side window shown in figure 1;
  • Figure 3-6 are schematic side views of a vehicle having a vehicle side window
  • Figure 7 is a schematic cross-sectional exploded representation of the vehicle side window shown in figure 2;
  • Figure 8a is a schematic cross-sectional representation of a stack of unlaminated component parts used to make the laminated glazing shown in figure 1 ;
  • Figure 8b is a schematic cross-sectional representation of a stack of unlaminated component parts used to make a laminated glazing similar to that shown in figure 1 ;
  • Figure 8c is a schematic plan-view of a portion of the unlaminated stack of components of figure 8b;
  • Figure 9 is a schematic isometric representation of the component parts used to make the laminated glazing 1;
  • Figure 10 is a schematic cross-sectional representation of a stack of unlaminated component parts used to make another laminated glazing in accordance with the present invention.
  • Figure 11 is a schematic cross-sectional representation of the stack of unlaminated component parts shown in figure 10 prior to being laminated together;
  • Figure 12 is a schematic cross-sectional representation of the laminated glazing made in accordance with the present invention with reference to figures 10 and 11.
  • non-chemically strengthened glass i.e. thermally toughened or strengthened soda-lime-silicate glass
  • DSR differential stress refractometer
  • Figure 1 shows a plan view of a vehicle side window 1 made using a method in accordance with the present invention.
  • the vehicle side window 1 has an upper region 3, a lower region 5 and a connection region 7.
  • the upper region 3 is defined in relation to a line x-x’, and the line x-x’ is defined by the styling of the vehicle into which the vehicle side window is installed, as will be discussed in more detail below.
  • the connection region 7 comprises a first trapezoidal portion 7a and a second trapezoidal portion 7b.
  • Each trapezoidal portion 7a, 7b has a respective hole 7c, 7d at the narrow end thereof.
  • the holes 7c, 7d are used to connect a winder mechanism (not shown) to the vehicle side window 1 to move the vehicle side window vertically, i.e. in the direction of arrow 8.
  • the vehicle side window 1 has a major surface 10 configured for use as an outer surface.
  • the major surface 10 has a central region 12, the central region being inboard of the periphery of the vehicle side window 1.
  • Figure 2 shows a schematic cross-sectional representation of the laminated glazing 1 taken along the line y-y’ in figure 1.
  • the line x’-x forms a horizontal plane with the line x-x ⁇
  • the regions 3, 5 and 7 are defined in the same way as with reference to figure 1.
  • the laminated glazing 1 has a first sheet of glass 14 joined to a second sheet of glass 15 by means of interlayer structure 16.
  • the first sheet of glass 14 has a first major surface 14a and a second opposing major surface (not labelled in this figure).
  • the second sheet of glass 15 has a first major surface (not labelled in this figure) and a second opposing major surface 15b.
  • the interlayer structure 16 consists of a first sheet of PVB 17 having a thickness of 0.76mm, a second sheet of PVB 18 having athickness of 0.76mm and a sheet of PET 19 having athickness of 400pm.
  • Each of the first and second sheets of PVB 17, 18 have a respective first major surface and opposing second major surface.
  • the sheet of PET 19 also has a first major surface and a second opposing major surface (labelled as 19b).
  • the sheet of PET 19 is a sheet of support material and is between the first and second sheets of PVB 17, 18. In the event of breakage of the first sheet of glass 14, the first and second sheets of PVB 17, 18 remained adhered to the sheet of PET 19 so that the second sheet of glass 15 does not become detached from the laminated glazing 1.
  • the sheet of PET 19 may have a solar control coating on at least a portion of a major surface thereof (i.e. major surface 19a and/or 19b - see figure 7).
  • the second sheet of PVB 18 is coextensive with the first sheet of glass 14.
  • the second sheet of PVB 18 may be slightly inboard the edge of the first sheet of glass 14, especially in the upper region 3.
  • the sheet of PET 19 is coextensive with the second sheet of PVB 18 and may be part of a composite structure, for example the sheet of PVB 18 may be joined to the sheet of PET 19 prior to laminating the first sheet of glass 14 to the second sheet of glass 15 by means of the interlayer structure 16. That is, the sheet of PET 19 may be j oined to the sheet of PVB 18 in the form of a composite structure of the type used for spall protection.
  • the exposed portion of the major surface 19b of the sheet of PET 19 may have an anti -abrasion hard coat or a solar control coating thereon.
  • a coating i.e. anti-abrasion or solar control
  • the first sheet of PVB 17 would be in direct contact with the coating instead of being in direct contact with the sheet of PET 19.
  • the first sheet of PVB 17 is coextensive with the second sheet of glass 15. However, the first sheet of PVB 17 and the second sheet of glass 15 are not coextensive with the first sheet of glass 14.
  • the first sheet of glass 14 is a sheet of soda-lime-silicate glass having a composition such as clear float glass, typically with the addition of iron oxide as a tinting agent to provide the laminated glazing with some form of solar control.
  • the first sheet of glass may have a different composition, such as a borosilicate glass composition or an aluminosilicate glass composition.
  • the first sheet of glass 14 has a thickness of 4.85 mm and has been thermally toughened using a conventional high pressure cooling air technique such that the compressive stress in at least the central region 12 of the first sheet of glass 14 is around 90 MPa.
  • the second sheet of glass 15 has a thickness of 0.6 mm but may have a thickness in the range of 0.3 mm to 0.8 mm, for example 0.4 mm to 0.8 mm.
  • the second sheet of glass 15 may have a thickness of 0.55mm or 0.7mm.
  • the second sheet of glass 15 has been chemically strengthened using a conventional molten salt ion exchange process to exchange sodium ions in the surface of the second sheet of glass with potassium ions from a suitable molten salt.
  • the chemical strengthening process is controlled to provide the second sheet of glass with a depth of layer (DOL) of 35 pm and a surface compressive stress greater than 400MPa, typically between 450MPa and 700MPa.
  • the surface compressive stress may be as high as 900MPa.
  • the DOL may be between 30pm and 40pm.
  • a specific composition for the second sheet of glass 15 is 68 mol% S1O2, 2.5 mol% AI2O3, 11 mol% MgO, 3.7 mol% CaO, 14.2 mol% Na 2 0, 0.6 mol% K2O.
  • MgO + CaO is 14.7 mol%
  • Na 2 0 + K2O is 14.8 mol%.
  • the iron oxide (Fe203) content of the second sheet of glass may be low, being less than 0.1 percent by weight i.e. about 0.012 percent by weight.
  • hole 7d passes through the first sheet of glass 14, the second sheet of PVB 18 and the sheet of PET 19.
  • part of the interlayer structure 16 extends below the line x’ -x” , and consequently below the line x-x’ in figure 1.
  • the second sheet of PVB 18 is coextensive with both the sheet of PET 19 and the first sheet of glass 14 (other than at the hole 7d).
  • the second sheet of PVB 18 and the sheet of PET 19 extend below the line x’-x” (and x’-x’ in figure 1) to cover the lower region 5, which includes the connection region 7.
  • the region of the hole 7d is also surrounded by PVB (from the second sheet of PVB 18) and PET (from the sheet of PET 19).
  • the hole 7d is still surrounded by PVB and PET but either or both the second sheet of PVB 18 and the sheet of PET 19 are not coextensive with the first sheet of glass 14.
  • the second sheet of PVB 18 may extend slightly below the hole 7d, or the second sheet of PVB may be coextensive with the first sheet of glass 14 whereas the sheet of PET 19 may extend below the line x’-x” but may not be coextensive with the second sheet of PVB 18.
  • the laminated glazing 1 has a first region 2 and a second region 6.
  • the first region 2 is essentially that part of the laminated glazing 1 where a portion of the interlayer structure 16 is between the first sheet of glass 14 and the second sheet of glass 15.
  • the first sheet of PVB 17 does not cover a portion of the second major surface of the first glass sheet 14.
  • the first region 2 includes the upper region 3 because the first region 2 extends below the lines x’-x” and x-x ⁇
  • the portion of the sheet of PET 19 not covered by the first sheet of PVB 17 and the second sheet of glass 15 may be used to define the second region 6 of the laminated glazing 1.
  • the first region 2 of the laminated glazing 1 has in sequence a first portion of the first sheet of glass 14, a first portion of the second sheet of PVB 18, a first portion of the sheet of PET 19, the first sheet of PVB 17 and the second sheet of glass 15.
  • a ray of light at normal incidence to the first major surface 14a of the first sheet of glass 14 in the first region 2 passes through the laminated glazing 1 by passing through, in sequence, the first sheet of glass 14, the second sheet of PVB 18, the PET sheet 19, the first sheet of PVB 17 and finally the second sheet of glass 15, to emerge from the second major surface 15b of the second sheet of glass 15.
  • the second region 6 of the laminated glazing 1 has in sequence a second portion of the first sheet of glass 14, a second portion of the second sheet of PVB 18 and a second portion of the sheet of PET 19, where the second portion of the sheet of PET 19 has an exposed portion of the second major surface 19b of the sheet of PET 19.
  • the exposed portion of the second major surface 19b of the sheet of PET 19 does not face the first sheet of glass 14 but faces away from the first sheet of glass 14.
  • the exposed portion of the second major surface 19b of the sheet of PET 19 is not covered by the first sheet of PVB 17 or the second sheet of glass 15.
  • the first region 2 includes the upper region 3 and it is important to have good optical quality in the upper region 3 (and the majority of the first region 2) because in use, this part of the laminated glazing is a through vision region of the laminated glazing i.e. is used for a person to see through.
  • the second region 6 is part of the lower region 5, and in use is not a through vision region so the transmission of visible light in this region is less important.
  • the optical quality in the first region 2 may be affected due to the lamination method used to produce the laminated glazing 1.
  • FIG 3 shows a schematic side view of a vehicle 50 (i.e. a car).
  • vehicle 50 i.e. a car
  • the vehicle 50 has a side door 52 and an aperture 54 having a periphery 56 in which a vehicle side window of the type shown in figures 1 and 2 is vertically movable therein in a manner known in the art.
  • the periphery 56 may be defined by part of the vehicle door i.e. a suitable frame, or a part of the vehicle body.
  • the periphery 56 has comers j, k and m.
  • the line j-m defines the position of the line x-x’ shown in figure 1.
  • the aperture 54 is shown in a closed configuration with the vehicle side window closing the aperture 54.
  • a portion of the major surface 10 of the first sheet of glass closes the aperture 54.
  • the vehicle 50 has a fixed side window 58 that may be made in accordance with the present invention.
  • the side window 58 is fixed in a frame, there is no need for the side window 58 to have a connection region for connecting a winder mechanism to the side window 58.
  • Figure 4 shows the vehicle 50 with the aperture 54’ in a second configuration with the vehicle side window wound fully down.
  • figure 5 shows vehicle 50 having a side door 52 incorporating a vehicle side window 1 movable in aperture 54.
  • the vehicle side window 1 below the line x-x’ i.e. the line j-m defined by the aperture
  • a suitable linkage 62 connects the winder mechanism 60 to the connection region of the vehicle side window 1.
  • a first linkage member 63 is in mechanical communication with the first trapezoidal portion 7a and a second linkage member 64 is in mechanical communication with the second trapezoidal portion 7b.
  • the holes 7c, 7d may be used to attach an end of the respective linkage member 63, 64 to the respective trapezoidal portion 7a, 7b.
  • the linkage member 63, 64 may be configured at one end thereof to pass through the respective hole and be secured to the first sheet of glass 14 by a clamping mechanism across the major surfaces thereof.
  • the aperture 54 is closed by the upper region 3 of the vehicle side window 1.
  • Figure 6 shows the vehicle 50 shown in figure 5 where the winder mechanism 60 has been suitably actuated to wind the vehicle side window partially down such that there is an opening 66 in the aperture 54 i.e. the aperture is no longer fully closed.
  • the winder linkage 62 moves from the first position shown in figure 5 to the second position shown in figure 6.
  • Each of the first and second linkages 63, 64 are suitably moved towards the winder mechanism 60 thereby lowering the vehicle side window in the aperture. Consequently, the line x-x’ on the vehicle side window 1 moves below the line j-m defined by the aperture 54.
  • the interior of the vehicle 50 is accessible via the opening 66.
  • Figure 7 is an exploded cross-sectional schematic view of the laminated glazing 1 shown in figure 2, but in a horizontal arrangement.
  • Figure 7 is illustrative of the individual components used to make up the laminated glazing 1 prior to the lamination method.
  • the first sheet of glass 14 has a first major surface 14a and a second opposing major surface 14b.
  • the second sheet of glass 15 has a first major surface 15a and a second opposing major surface 15b.
  • the second major surface 14b of the first sheet of glass 14 faces the first major surface 15a of the second sheet of glass 15.
  • the first sheet of PVB 17 has a first major surface 17a and a second opposing major surface 17b.
  • the sheet of PET 19 has a first major surface 19a and a second opposing major surface 19b.
  • the second sheet of PVB 18 has a first major surface 18a and a second opposing major surface 18b.
  • Each of the first sheet of glass 14, the second sheet of PVB 18 and the sheet of PET 19 have a respective hole 14d, 18d, 19d therein, and the holes 14d, 18d, 19d align in the laminated glazing 1 to form hole 7d.
  • the holes 14d, 18d, 19d are all circular but they may have other shapes. Also, in this example the holes 14d, 18d, 19d all have the same diameter.
  • the hole 18d is an opening in the second sheet of PVB 18.
  • the hole 19d is an opening in the sheet of PET 19.
  • the first sheet of glass 14 is initially placed onto a suitable support such that the second major surface 14b of the first sheet of glass faces upwards.
  • the second sheet of PVB 18 is placed onto the first sheet of glass 14 such that the second major surface 18b faces upwards and the hole 18d is aligned with the hole 14d in the first sheet of glass.
  • the periphery of the second sheet of PVB 18 is aligned with the periphery of the first sheet of glass 14 i.e. the second sheet of PVB 18 is congruently stacked on the first sheet of glass 14.
  • an over-sized sheet of PVB 28 may be used instead of a pre-cut sheet of PVB 18.
  • the over-sized sheet of PVB 28 is positioned on the first sheet of glass 14 and cut to size by trimming off the excess PVB 28’ using the periphery of the first sheet of glass 14 as a template.
  • a sheet of PET 19 is placed on the second sheet of PVB 18 such that the hole 19d therein is aligned with the hole 18d and the second major surface 19b faces upwards.
  • the periphery of the sheet of PET 19 is aligned with the periphery of the second sheet of PVB 18 i.e. the first sheet of glass 14, the second sheet of PVB 18 and the sheet of PET 19 are congruently stacked.
  • an over-sized sheet of PET 29 may be used instead of a pre-cut sheet of PET 19.
  • the over-sized sheet of PET 27 is positioned on the first sheet of PVB 17 and cut to size by trimming off the excess PET 29’ using the periphery of the first sheet of glass 14 with first sheet of PVB thereon as a template.
  • first sheet of PVB 17 is placed on the second major surface 19b such that the second major surface 17b faces upwards.
  • Three sides of the periphery of the first sheet of PVB 17 are aligned with portions of the periphery of the sheet of PET 19.
  • the second sheet of glass 15 is positioned on the first sheet of PVB 17.
  • the periphery of the second sheet of glass 15 is aligned with the periphery of the first sheet of PVB 17 i.e. the second sheet of glass 15 is congruently stacked with the first sheet of PVB 17.
  • the first major surface 15a of the second sheet of glass 15 faces the second major surface 14b of the first sheet of glass 14.
  • a spacer 20 is positioned on the exposed part of the PET (the portion of the PET sheet 19 not covered by the first sheet of PVB 17 and the second glass sheet 15). As shown in figure 8, the spacer 20 is moved in the direction of arrow 22 onto the exposed portion of the second major surface 19b of the sheet of PET 19.
  • the spacer 20 was made of polycarbonate although other plastic material may be used.
  • the spacer 20 may be made of a synthetic rubber material, for example EPDM.
  • the spacer 20 has a first major surface 20a and a second opposing major surface 20b.
  • the shape of the major surface 20a is configured to nest with the sheet of PET 19 on the second sheet of PVB 18 and the first sheet of glass 14 in the second region 6.
  • the second sheet of PVB 18 and the sheet of PET 19 each have major surfaces that are parallel to each other. Accordingly, the shape of the major surface 20a is configured to nest with the first sheet of glass 14 in the second region 6.
  • the thickness of the spacer 20 is substantially the same as the combined thickness of the second sheet of glass 15 and the first sheet of PVB 17.
  • the spacer preferably has a thickness of 1.08mm.
  • the second major surface 20b of the spacer 20 is aligned with the second major surface 15b of the second sheet of glass 15 when positioned on the exposed portion of the sheet of PET 19. If additional glass/PVB sheets are on the second sheet of glass 15 the spacer preferably has a thickness the same, or substantially the same, as a combined thickness of all said sheets of PVB/glass, which includes the first sheet of PVB 17 and the second sheet of glass 15.
  • the spacer is used to avoid a step between the second major surface 15b of the second sheet of glass 15 (which is an exposed inner or outer pane of the laminated glazing) and the second major surface 19b of the sheet of PET 19.
  • the periphery of the spacer 20 may be aligned with the periphery of the sheet of PET 19 in the second region 6.
  • the spacer 20 may be replaced by a spacer 201.
  • the spacer 201 has a similar periphery to the spacer 20 but is not aligned with the spacer between the two trapezoidal portions 7a and 7b.
  • a spacer 202 may be used which has a rectangular outline periphery.
  • a minor face 20’ of the spacer 20 is adjacent the minor faces 17’ and 15’ of the first sheet of PVB 17 and the second sheet of glass 15 respectively.
  • the minor face 20’ of the spacer may directly contact the minor face 15’ of the second sheet of glass 15 and/or the minor face 17’ of the first sheet of PVB 17. It is preferred for there to be a gap between the minor faces 15 ’ and 17’ and the minor face 20’ i.e. the spacer 20 is spaced apart from the first sheet of PVB 17 and the second sheet of glass 15 when the spacer 20 is on the exposed portion of the second major surface 19b of the sheet of PET 19. By having such a gap, it is easier to de-air the unlaminated stack during lamination.
  • the spacer 20 may have a portion extending from the first major surface 20a thereof for extending into the hole 7d when the spacer is positioned on the exposed portion of the PET 19. This may help locate the spacer 20 in the preferred position on the exposed portion of the PET 19. The provision of such a portion extending from the first major surface 20a of the spacer 20 may also act as a barrier to prevent interlayer material from the second sheet of adhesive interlayer material flowing into hole 7d.
  • a mould 23 is then positioned on the second sheet of glass 15 and the spacer 20 by moving the mould 23 in the direction of arrow 24.
  • the mould is a glass sheet having smooth major surfaces.
  • Other material that is dimensionally stable during the lamination process may be used for the mould, for example stainless steel.
  • the mould 23 is preferably made of a material that does not adhere to the second sheet of glass 15 or the spacer 20. In this example the mould 23 does not adhere to the second major surface 15b of the second sheet of glass 15 or to the second major surface 20b of the spacer 20.
  • the mould 23 is used to press against the second sheet of glass 15 and spacer 20 especially during the lamination process.
  • first sheet of glass 14, second sheet of PVB 18, sheet of PET 19, first sheet of PVB 17 and second sheet of glass 15 prior to lamination may be referred to as an unlaminated stack.
  • the unlaminated stack including the spacer and mould in position as described above is then laminated at a temperature in the range 90 °C to 140 °C and a pressure in the range 8 bar to 16 bar. Lamination is possible at a higher temperature, but this is not desirable due to potentially affecting the optical quality in the first region 2 and/or the increased energy usage required to produce the laminated glazing.
  • the mould 23 may be removed from the second sheet of glass 15 and the spacer 20 because the mould does not adhere thereto during the lamination process.
  • the spacer 20 may be removed from the exposed portion of the second major surface 19b of the sheet of PET 19 because the spacer 20 does not adhere thereto.
  • a spacer that includes a releasable adhesive layer may be used in the present invention but is less preferred as such a spacer may be more difficult to remove from the exposed portion of the second major surface 19b of the sheet of PET 19 following lamination.
  • mould 23 in addition to a mould 23 being used to press against the second sheet of glass 15 and the spacer 20, another mould is used to press against the first sheet of glass 14.
  • This additional mould is shown in figure 9 in phantom and is labelled 231.
  • the mould 231 may be used to press against the first major surface 14a of the first sheet of glass 14 during lamination, and the unlaminated stack may be laid up on the mould 231 prior to the mould 23 being included.
  • the mould 231 may be made of the same material as the mould 23 and may have a shape configured for the first sheet of glass 14 to nest therein.
  • the spacer 20 has a pattern on the first major surface 20a. It was found that upon pressing the spacer 20 against the exposed portion of the second major surface 19b of the sheet of PET 19 (i.e. the first major surface 20a of the spacer being in contact with the exposed portion of the second major surface 19b of the sheet of PET 19), the pattern on the first major surface 20a of the spacer 20 was transferred to the portion of the interlayer structure in the second region 6. The pattern on the first maj or surface 20a was transferred to the sheet of PET 19 and/or the second sheet of PVB 18 in the second region 6.
  • the pattern on the first major surface 20a of the spacer 20 may also, or instead of, be in the first major surface 20a.
  • Using such a patterned spacer provides a method for providing the laminated glazing 1 with a pattern in the second region.
  • Such a pattern may be in the form of text and/or a picture.
  • the hole 18d in the second sheet of PVB 18 and the hole 19d in the sheet of PET 19 have a larger diameter than the hole 14d in the first sheet of glass 14.
  • both the holes 18d and 19d have the same diameter.
  • the centre of the holes 18d, 19d and the hole 14d in the first sheet of glass 14 are all aligned to create a through hole 7d ⁇
  • a portion of the second major surface 14b of the first sheet of glass 14 is accessible through the holes 18d, 19d.
  • FIG. 8c is a view of the laminated glazing G in the direction of arrow 22.
  • a linkage member may be attached to the first sheet of glass 14 by passing through the hole 7d’ and clamping across portions of the first major surface 14a and second major surface 14b (i.e. portion 14b*) adjacent the ends of the hole 14d.
  • void in the first sheet of PVB 18 and sheet of PET 19 may be provided (i.e. square, rectangular, triangular, multi-sided) instead to allow access to a portion of the second major surface 14b of the first sheet of glass adjacent the end of the hole 14d in the second major surface 14b. Provision of such voids in the first sheet of PVB 18 and sheet of PET 19 allow a linkage member to be attached to the first sheet of glass 14 by passing through the hole 14d and clamping across portions of the first and second major surfaces 14a, 14b adjacent the ends of the hole 14d.
  • the spacer may be configured with a portion extending from the first major surface 20a thereof to fit in the holes 18d, 19d preferably to contact the second major surface 14b when the spacer is positioned on the exposed part of the sheet of PET 19.
  • a spacer is labelled 20” and has a first major surface 20a’, a second major surface 20b’ and a portion 20c’ extending from the first major surface 20a’.
  • the first major surface 20b’ is substantially flat.
  • the portion 20c’ has a flat region 20d’ at an end thereof.
  • the spacer 20 is configured such that the portion 20c’ nests with the hole 18d and/or 19d.
  • the spacer 20” does not have a uniform thickness but is still configured such that the second major surface 20b’ aligns with the second major surface 15b of the second sheet of glass 15.
  • the portion 20c’ of the spacer extending away from the first major surface 20a’ may extend up to 0.80mm from the first major surface 20a’.
  • first major surface 20a’ of the spacer 20 can rest on the exposed portion of the sheet of PET 19 and the flat region 20’ can rest on the portion 14b* of the second major surface 14b.
  • the separation between the first and second major surfaces 20a’, 20b’ of such a spacer 20” would be substantially the same as the combined thickness of the second sheet of glass 15 and the first sheet of PVB 17 so that the second major surface 20b’ is aligned, or substantially aligned with the second major surface 15 of the second sheet of glass 15.
  • Such a portion 20c’ extending from the first major surface 20a’ of the spacer 20” may also assist with aligning the spacer 20” on the exposed portion of the sheet of PET 19 because said portion 20c’ essentially acts as a locating pin with the opening in the sheet of support material and the opening in the second sheet of adhesive interlayer material.
  • Such a portion 20c’ extending from the first major surface 20a’ of the spacer 20” may also act as a barrier to prevent material from the second sheet of adhesive interlayer material 18 flowing into hole 7d’.
  • the vehicle side window 1 is shown as being flat (or planar) having a flat outer surface, the vehicle side window 1 may be curved in one or more directions.
  • the radius of curvature in one of the one or more directions may be between 1000mm and 8000mm.
  • each direction of curvature is orthogonal to the other.
  • the radius of curvature in one or both directions of curvature is between 1000mm and 8000mm.
  • the second sheet of glass may be initially flat and “cold formed” to the desired shape set by the curved first sheet of glass by applying suitable pressure to the flat second sheet of glass during the lamination process.
  • the temperature during the lamination process is sufficient to cause to the adhesive layer (i.e. a sheet of PVB) to bond to the first and second sheets of glass, but such temperature is not sufficient to cause the second sheet of glass alone to be deformed by pressing between complementary shaping members and/or sagging under the influence of gravity.
  • the spacer When the first sheet of glass is curved, the spacer may be curved to nest with the first sheet of glass in the second region of the resulting laminated glass, or the spacer may be shaped differently and have a curvature imposed thereon by the first sheet of glass and suitable mould 23.
  • Figure 10 shows a schematic exploded cross-sectional view of another laminated glazing 100 made in accordance with the present invention.
  • the laminated glazing 100 comprises a first sheet of glass 114 joined to a second sheet of glass 115 by means of a sheet of EVA 117.
  • the first sheet of glass 114 has a first major surface 114a and a second opposing major surface 114b.
  • the sheet of EVA 117 has a first major surface 117a and a second opposing major surface 117b.
  • the second sheet of glass 115 has a first major surface 115a and a second opposing major surface 115b.
  • the laminated glazing 110 is arranged such that the second major surface 114b of the first sheet of glass 114 faces the first major surface 117a of the sheet of EVA 117.
  • the second major surface 117b of the sheet of EVA 117 faces the first major surface 115a of the second sheet of glass 115. Consequently, the second major surface 114b of the first sheet of glass 114 faces the first major surface 115a of the second sheet of glass 115.
  • the sheet of EVA 117 is coextensive with the second sheet of glass 115. Three edges of the sheet of EVA 117 and the second sheet of glass 115 are aligned with portions of three edges of the first sheet of glass 114.
  • the laminated glazing 100 has two region 102, 106.
  • the first region 102 includes the sheet of EVA 117 between the second sheet of glass 115 and a portion of the first sheet of glass 114.
  • the sheet of EVA 117 and the second sheet of glass 115 do not cover the first sheet of glass 114.
  • the laminated glazing 100 is made as follows and with reference to figures 10, 11 and 12.
  • a mould 31 is positioned on a flat surface.
  • the first sheet of glass 114 is position on the mould 31 such that the second major surface 114b faces upwards.
  • the sheet of EVA 117 is positioned on the first sheet of glass 114 such that a first portion of the second major surface 114b is covered by the sheet of EVA 117. A second portion of the second major surface 114b of the first sheet of glass 114 is not covered by the sheet of EVA 117.
  • the second sheet of glass is positioned on the sheet of EVA 117.
  • a plastic spacer 120 having first and second opposed major surfaces 120a, 120b is positioned on the second major surface 114b of the first sheet of glass 114 in the second region 106 i.e. in the direction of arrow 122. That is, the plastic spacer 120 is positioned on the second portion major of the second major surface 114b of the first sheet of glass 114.
  • a second mould 33 is positioned on the second sheet of glass 115 and the spacer 120.
  • the unlaminated stack including the spacer 120 and moulds 31, 33 is then subjected to a lamination process at a temperature in the range 80 °C to 110 °C and a pressure in the range 8 bar to 16 bar.
  • the first mould 31 presses against the first sheet of glass 114 in the direction of arrow 124 and the second mould 33 presses against the second sheet of glass 115 and the spacer 120 in the direction of arrow 126.
  • the moulds 31, 33 are removed and the spacer 120 is removed from the first sheet of glass 114 i.e. in direction of arrow 128.
  • Figure 12 also illustrates the slight gap 130 between the edge of the spacer 120 and the edges of the second sheet of glass 115 and the sheet of EVA 117.
  • the gap 130 helps de-airing during lamination.
  • the present invention provides methods for making a laminated glazing comprising a first sheet of glass joined to a second sheet of glass by means of an interlayer structure therebetween.
  • an unlaminated stack Prior to lamination, an unlaminated stack is formed where a first portion of a major surface of the first sheet of glass is covered by a portion of the interlayer structure and a second portion of the major surface of the first sheet of glass is not covered by the interlayer structure; the second sheet of glass is on the interlayer structure; and the spacer is on the second portion of the major surface of the first sheet of glass and is at least partially aligned with a major surface of the second sheet of glass not facing the interlayer structure. Following lamination, the spacer is removed from the laminated glazing.
  • the present invention finds particular application in the field of vehicle glazings, especially vehicle side windows that may be movable within an aperture in the vehicle or fixed in an aperture in the vehicle.
  • the laminated glazings may be used in the rear of a vehicle (i.e. as part or all of a vehicle backlight) or in the roof of a vehicle.
  • a laminated glazing made according to the present invention has improved optical quality in the aperture region of the glazing.

Landscapes

  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Joining Of Glass To Other Materials (AREA)

Abstract

Methods for making a laminated glazing comprising a first sheet of glass joined to a second sheet of glass by means of an interlayer structure therebetween are described. Prior to lamination, an unlaminated stack is formed where a first portion of a major surface of the first sheet of glass is covered by a portion of the interlayer structure and a second portion of the major surface of the first sheet of glass is not covered by the interlayer structure; the second sheet of glass is on the interlayer structure; and the spacer is on the second portion of the major surface of the first sheet of glass and is at least partially aligned with a major surface of the second sheet of glass not facing the interlayer structure. Following lamination, the spacer is removed from the laminated glazing.

Description

METHOD FOR MAKING A LAMINATED GLAZING
The present invention relates to a method for making a laminated glazing, in particular a light weight laminated glazing for use in a vehicle.
It is well known that laminated glazings are used as windows in automotive vehicles. Usually the window is the vehicle windscreen, but may be a vehicle side window, rear window or sunroof. In the art a vehicle side window may be referred to as a vehicle side light. Typically, the vehicle has at least one, usually two, movable side windows, one on either side of the vehicle i.e. the passenger side and the driver side. In addition to movable side windows, there may be one or more fixed side windows, for example front or rear quarter lights.
In the driver’s door there is usually a side window that is movable in a vertical direction by actuation of a suitable winder mechanism. The winder mechanism may be manually or electrically operated and has at least one element in mechanical communication with the side window to move the side window within the vehicle aperture region defining the driver’s side window.
It is known that a vehicle side window may comprise a sheet of thermally toughened glass. When such a thermally toughened sheet of glass is broken, the integrity of the vehicle side window is lost as the sheet of glass is broken into many small fragments.
In order to reduce the weight of a vehicle side window it is known to use thin sheets of glass that are laminated together by means of an adhesive interlayer such as polyvinyl butyral (PVB). It is known to vary the compressive stress in at least one of the sheets of glass of the laminate to provide desirable mechanical characteristics.
It is also known that the laminated side window may have a construction such that when the side window is fully closed, the sheet of glass facing the interior of the vehicle does not extend fully downwards to the winder mechanism. Instead the winder mechanism is only connected to a connector region that is part of the outer sheet of glass of the laminated glazing. Actuation of the winder mechanism still moves the inner sheet of glass at the same time as the outer sheet of glass because the outer sheet of glass is joined to the inner sheet of glass by the adhesive interlayer material (such as PVB). However, the winder mechanism is not in direct physical contact with the inner sheet of glass.
It is also known to use a sheet of chemically strengthened glass as an inner facing sheet in a vehicle side window, for example as described in US4,985,099 and US2015/0224855A1. The sheet of chemically strengthened glass may be coextensive with the outer pane of glass or may only cover the aperture region of the vehicle when the side window is in a closed position as described above. JPS58-199752A1 discloses a laminated glazing where a spacer is used in the production thereof. An intermediate fdm of polyvinyl butyral having external dimensions less than those of a first glass sheet is placed on the first glass sheet and a release type soft spacer is disposed in the marginal part at the peripheral edge of the first glass plates where there is no intermediate film. A second glass plate is placed on the intermediate film and the spacer, after which a lamination process is used to join the first glass plate to the second glass plate by the intermediate film. The spacer is removed following lamination and a moisture impermeable sealant is positioned in the void left between the first and second glass pates upon removal of the spacer. In such a process it may be difficult to remove the spacer because the lamination process may cause the first and second glass plates to essentially clamp the spacer therebetween.
A problem when the inner facing sheet of a laminated side window for a vehicle only covers the aperture portion of the door is that upon lamination, there may be uneven lamination stress with an increased risk of delamination and/or reduced optical quality in the aperture region.
The present invention aims to at least partially overcome these problems.
Accordingly from a first aspect the present invention provides a method for making a laminated glazing comprising the steps: (i) providing a first sheet of glass having a first major surface and a second opposing major surface, an interlayer structure comprising at least a first sheet of adhesive interlayer material, a second sheet of glass having a first major surface and a second opposing major surface and a spacer having a first major surface and a second opposing major surface; (ii) positioning the interlayer structure, the spacer and the second sheet of glass on the second major surface of the first sheet of glass such that a first portion of the second major surface of the first sheet of glass is covered by at least a portion of the interlayer structure and a second portion of the second major surface of the first sheet of glass is not covered by the interlayer structure, the second sheet of glass is on the interlayer structure and the first major surface of the second sheet of glass faces the second major surface of the first sheet of glass and the spacer is on the second portion of the second major surface of the first sheet of glass and the second major surface of the spacer is at least partially aligned with the second major surface of the second sheet of glass; (iii) using suitable lamination conditions to laminate the first sheet of glass to the second sheet of glass via the interlayer structure; and (iv) removing the spacer from the laminated glazing.
A laminated glazing made using a method according to the first aspect of the present invention has at least two regions, a first region comprising in sequence the first sheet of glass, the first sheet of adhesive interlayer material and the second sheet of glass, and a second region that does not include the second sheet of glass and/or the first sheet of adhesive interlayer material as a part thereof.
By using a spacer in accordance with the method of the first aspect of the present invention, the optical quality of the laminated glazing in the first region thereof is higher than making the same laminated glazing without using a spacer. Optical quality may be assessed using methods known in the art, such as described in W02004/083835A1 or US5,694,479.
It is to be understood within the context of the present invention that when the spacer is on the second portion of the second major surface of the first sheet of glass, this does not rule out the possibility of there being one or more other layers of material (for example glass sheets, sheets of adhesive or non adhesive interlayer material, coatings etc) between the spacer and the second portion of the second major surface of the first sheet of glass. Accordingly, within the context of the present invention, when feature A is on feature B, this does not exclude features C, D, E ... etc being in between feature A and feature B.
Preferably following step (ii) the spacer is in direct contact with the second portion of the second major surface of the first sheet of glass.
Preferably during step (iii) the first sheet of glass is laminated to the second sheet of glass via the interlayer structure by laminating at a temperature at least 5 °C higher than the softening temperature of the first sheet of adhesive interlayer material, preferably at least 10 °C higher than the softening temperature of the first sheet of adhesive interlayer material.
Preferably during step (iii) the first sheet of glass to the second sheet of glass via the interlayer structure is carried out at a temperature in the range 60 to 150 °C, preferably 90 to 140 °C.
Preferably during step (iii) laminating the first sheet of glass to the second sheet of glass via the interlayer structure is carried out at a pressure in the range 5 to 20 bar, preferably 5 to 16 bar.
Preferably the spacer covers the entire second portion of the second major surface of the first sheet of glass, although in a preferred embodiment the spacer is sufficiently spaced from the interlayer structure to allow de-airing of the unlaminated stack during step (iii).
Each of the second sheet of glass and the interlayer structure has a respective thickness. Preferably spacer has a thickness that is substantially the same, or the same, as the combined thickness of the second sheet of glass and the interlayer structure.
The spacer has an outer periphery and the second portion of the second major surface of the first sheet of glass has an outer periphery. Preferably the outer periphery of the spacer is alignable with at least part of the outer periphery of the second portion of the sheet of support material.
Preferably the spacer comprises a releasable adhesive on at least a portion of the first and/or second major surface thereof. By using a releasable adhesive on the first and/or second major surface of the spacer it is possible to temporarily maintain the position of the spacer relative to the second portion of the second major surface of the first sheet of glass prior to and/or during and/or after step (iii). In some embodiments there are one or more intervening layers between the spacer and the second portion of the second major surface of the first sheet of glass.
Preferably the one or more intervening layers may have one or more opening therein, and an opening in each layer may be aligned with an opening in a successive layer such that a hole extends through successive layers and preferably opens onto the second major surface of the first sheet of glass.
In such embodiments, the spacer may comprise a portion extending from the first major surface thereof to extend into the aligned openings when the spacer is on the interlayer structure, and preferably the portion extending from the first major surface of the spacer contacts the second major surface of the first sheet of glass when the spacer is positioned on the interlayer structure.
In some embodiments, the interlayer structure comprises a second sheet of adhesive interlayer material and following step (ii), the second sheet of adhesive interlayer material is between the first sheet of glass and the first sheet of adhesive interlayer material and the first sheet of adhesive interlayer material is between the second sheet of glass and the second sheet of adhesive interlayer material.
Preferably the second sheet of adhesive interlayer material comprises polyvinyl butyral (PVB), acoustic modified PVB, polyurethane (PU) or a copolymer of ethylene such as ethylene vinyl acetate (EVA).
Preferably the second sheet of adhesive interlayer material has a thickness between 0.3mm and 2.3mm, more preferably between 0.3mm and 1.6mm, even more preferably between 0.3mm and 0.9mm.
Preferably the entire second portion of the second major surface of the first sheet of glass is covered by at least a portion of the second sheet of adhesive interlayer material, more preferably the entire second major surface of the first sheet of glass is covered by at least a portion of the second sheet of adhesive interlayer material.
Preferably the second sheet of adhesive interlayer material is coextensive with the second sheet of glass.
In some embodiments when the interlayer structure comprises a first and second sheet of adhesive interlayer material, the second sheet of adhesive interlayer material has an opening therein and following step (vii) the spacer covers the opening in the second sheet of adhesive interlayer material.
Preferably the spacer is configured with a portion extending from the first major surface thereof and following step (vii) the portion extending from the first major surface of the spacer is positioned in the opening in the second sheet of adhesive interlayer material. Preferably the portion extending from the first major surface of the spacer directly contacts the second major surface of the first sheet of glass.
In some embodiments the interlayer structure comprises a sheet of support material between the first sheet of adhesive interlayer material and a second sheet of adhesive interlayer material.
Preferably the second sheet of adhesive interlayer material comprises polyvinyl butyral (PVB), acoustic modified PVB, polyurethane (PU) or a copolymer of ethylene such as ethylene vinyl acetate (EVA).
Preferably the second sheet of adhesive interlayer material has a thickness between 0.3mm and 2.3mm, more preferably between 0.3mm and 1.6mm, even more preferably between 0.3mm and 0.9mm.
Preferably the second sheet of adhesive interlayer material is coextensive with the sheet of support material.
Preferably the second sheet of adhesive interlayer material is coextensive with the sheet of support material and the first sheet of glass.
Preferably the second sheet of adhesive interlayer material is coextensive with the sheet of support material and the first sheet of glass, and the first sheet of adhesive interlayer material is coextensive with second sheet of glass.
Preferably the sheet of sheet of support material has a higher rigidity than the first and/or second sheets of adhesive interlayer material.
Preferably the sheet of support material is more dimensionally stable than the first and/or second sheets of adhesive interlayer material.
Preferably the sheet of support material is stiffer than the first and/or second sheets of adhesive interlayer material.
Preferably the sheet of support material has a higher rigidity than the first and/or second sheets of adhesive interlayer material. In order to determine that the sheet of support material has a higher rigidity that the first and/or second layer of adhesive interlayer material, the rigidity of the sheet of support material and the first and/or second sheet of adhesive interlayer material may be determined prior to being incorporated into the laminated glazing. Standard methods in the art may be used to determine rigidity.
Preferably the sheet of support material is more dimensionally stable than the first and/or second sheets of adhesive interlayer material. The dimensional stability of a material may be measured using a standard method, for example as defined in ASTM D1204 and may be carried out at one or more temperature between 50-150 °C. Dimensional stability may be determined prior to being incorporated into the laminated glazing.
Preferably the sheet of support material is stiffer than the first and/or second sheets of adhesive interlayer material. Stiffness may be determined by measuring the extent to which the sample under investigation deforms in response to an applied force. Relative stiffness between the sheet of support material and the first and/or second layer of adhesive interlayer material may be determined prior to being incorporated into the laminated glazing using standard methods known in the art.
Preferably the sheet of support material comprises a material having a Young’s modulus (often referred to as Modulus of Elasticity, E) between x GPa and y GPa, wherein x is 0.1, 0.2, 0.3, 0.4, 0.5, 1.0 or 1.5 andy is 10, 20, 30, 40, 50, 60, 70, 80, 90 or 100. For example, preferably the sheet of support material comprises a material having a Young’s modulus (E) between 0.1 GPa and 100 GPa. Young’s modulus may be determined using standard methods known in the art.
Preferably the sheet of support material has a Young’s modulus between 0.1 GPa and 100 GPa.
Dynamic mechanical properties may be determined in accordance with a standard method such as ASTM D4065.
It is known in the art that the Young’s Modulus of an adhesive interlayer material such as polyvinyl butyral may be determined as a function of temperature and load duration or frequency.
Preferably the sheet of support material comprises a polyester.
Preferably the sheet of support material comprises polyethylene terephthalate (PET).
Preferably the sheet of support material comprises a sheet of glass.
Preferably the sheet of support material comprises an ionoplast interlayer material such as SentryGlas®.
Preferably the sheet of support material is monolithic
Preferably the sheet of support material is multi-layered. When the sheet of support material is multi-layered, the sheet of support material comprises at least two layers (a first layer and a second layer) that are the same material or are of different materials.
Preferably the sheet of support material has a thickness between 20pm and 1000pm, more preferably between 50pm and 500pm. Preferably the sheet of support material is thinner than the second sheet of glass and the second sheet of glass is thinner than the first sheet of glass.
Preferably the sheet of support material has a coating on at least a portion of a major surface thereof. The coating on the major surface of the sheet of support material may cover the entire major surface of the sheet of support material and/or may be a solar control coating and may comprise one or more layer of silver.
Preferably following step (ii), a first portion of the sheet of support material is between the first and second sheets of adhesive interlayer material and a second portion of the sheet of support material is not between the first and second sheets of interlayer material such that the second portion of the sheet of support material comprises an exposed surface. In such embodiments, it is preferred that at least a portion of the second portion of the second major surface of the first sheet of glass is covered by at least a portion of the second portion of the sheet of support material. It is preferred that the entire second portion of the second major surface of the first sheet of glass is covered by at least a portion of the second portion of the sheet of support material.
Preferably following step (ii) the spacer is in direct contact with the second portion of the sheet of support material.
Preferably the sheet of support material has an opening therein and the opening in the sheet of support material is covered by the spacer following step (ii).
Preferably the second sheet of adhesive interlayer material has an opening therein, and the opening in the second sheet of adhesive interlayer material is at least partially aligned with an opening in the sheet of support material.
Preferably the spacer comprises a portion extending from the first major surface thereof and the portion extending from the first major surface of the spacer at least partially extends into the opening in the sheet of support material following step (ii).
When the second sheet of adhesive interlayer material has an opening therein, and the opening in the second sheet of adhesive interlayer material is at least partially aligned with an opening in the second sheet of adhesive interlayer material, preferably the portion extending from the first major surface of the spacer at least partially extends into the opening in the second sheet of adhesive interlayer material. In such embodiments, it is preferred that the portion extending from the first major surface of the spacer contacts the second major surface of the first sheet of glass following step (ii). In some embodiments the interlayer structure is first positioned on the second major surface of the first sheet of glass, then the second sheet is glass positioned on the interlayer structure, and then the spacer is positioned on the second major surface of the first sheet of glass.
Accordingly, in such embodiments of the first aspect of the present invention there are provided methods for making a laminated glazing comprising the steps: (a) providing a first sheet of glass having a first major surface and a second opposing major surface; (b) providing an interlayer structure, the interlayer structure comprising at least a first sheet of adhesive interlayer material; (c) positioning the interlayer structure on the second major surface of the first sheet of glass such that a first portion of the second major surface of the first sheet of glass is covered by at least a portion of the first sheet of adhesive interlayer material and a second portion of the second major surface of the first sheet of glass is not covered by the first sheet of adhesive interlayer material; (d) providing a second sheet of glass having a first major surface and a second opposing major surface; (e) positioning the second sheet of glass on the interlayer structure such that the first major surface of the second sheet of glass faces the second major surface of the first sheet of glass; (f) providing a spacer having a first major surface and a second opposing major surface; (g) positioning the spacer on the second portion of the second major surface of the first sheet of glass, the spacer being configured such that the second major surface of the spacer is at least partially aligned with the second major surface of the second sheet of glass when the spacer is on the second portion of the second major surface of the first sheet of glass and the first major surface of the spacer faces the second major surface of the first sheet of glass; (h) using suitable lamination conditions to laminate the first sheet of glass to the second sheet of glass via the interlayer structure; and (j) removing the spacer from the laminated glazing.
The interlayer structure may be provided at any time prior to being positioned on the second major surface if the first sheet of glass.
The second sheet of glass may be provided at any time prior to being positioned on the interlayer structure.
The spacer may be provided at any time prior to being positioned on the second portion of the second major surface of the first sheet of glass.
In some embodiments the interlayer structure is first positioned on the second major surface of the first sheet of glass, then the spacer is positioned on the second major surface of the first sheet of glass, and then the second sheet of glass positioned on the interlayer structure.
Accordingly, in such embodiments of the first aspect of the present invention there are provided methods for making a laminated glazing comprising the steps: (a) providing a first sheet of glass having a first major surface and a second opposing major surface; (b) providing an interlayer structure, the interlayer structure comprising at least a first sheet of adhesive interlayer material; (c) positioning the interlayer structure on the second major surface of the first sheet of glass such that a first portion of the second major surface of the first sheet of glass is covered by at least a portion of the first sheet of adhesive interlayer material and a second portion of the second major surface of the first sheet of glass is not covered by the first sheet of adhesive interlayer material; (d) providing a spacer having a first major surface and a second opposing major surface; (e) positioning the spacer on the second portion of the second major surface of the first sheet of glass; (f) providing a second sheet of glass having a first major surface and a second opposing major surface; (g) positioning the second sheet of glass on the interlayer structure such that the first major surface of the second sheet of glass faces the second major surface of the first sheet of glass, the spacer being configured such that the second major surface of the spacer is at least partially aligned with the second major surface of the second sheet of glass when the spacer is on the second portion of the second major surface of the first sheet of glass and the first major surface of the spacer faces the second major surface of the first sheet of glass; (h) using suitable lamination conditions to laminate the first sheet of glass to the second sheet of glass via the interlayer structure; and (j) removing the spacer from the laminated glazing.
The interlayer structure may be provided at any time prior to being positioned on the second major surface if the first sheet of glass.
The spacer may be provided at any time prior to being positioned on the second portion of the second major surface of the first sheet of glass.
The second sheet of glass may be provided at any time prior to being positioned on the interlayer structure.
In some embodiments the spacer is first positioned on the second major surface of the first sheet of glass, then the interlayer structure is positioned on the second major surface of sheet of glass, and then the second sheet of glass positioned on the interlayer structure.
Accordingly, in such embodiments of the first aspect of the present invention there are provided methods for making a laminated glazing comprising the steps: (a) providing a first sheet of glass having a first major surface and a second opposing major surface; (b) providing a spacer having a first major surface and a second opposing major surface; (c) positioning the spacer on the second major surface of the first sheet of glass such that a first portion of the second major surface of the first sheet of glass is not covered by the spacer and a second portion of the second major surface of the first sheet of glass is covered by at least a portion of the spacer and the first major surface of the spacer faces the second major surface of the first sheet of glass; (d) providing an interlayer structure, the interlayer structure comprising at least a first sheet of adhesive interlayer material; (e) positioning the interlayer structure on the first portion of the second major surface of the first sheet of glass; (f) providing a second sheet of glass having a first major surface and a second opposing major surface; (g) positioning the second sheet of glass on the interlayer structure such that the first major surface of the second sheet of glass faces the second major surface of the first sheet of glass, the spacer being configured such that the second major surface of the spacer is at least partially aligned with the second major surface of the second sheet of glass when the second sheet of glass is positioned on the interlayer structure; (h) using suitable lamination conditions to laminate the first sheet of glass to the second sheet of glass via the interlayer structure; and (j) removing the spacer from the laminated glazing.
The spacer may be provided at any time prior to being positioned on the second major surface of the first sheet of glass.
The interlayer structure may be provided at any time prior to being positioned on first portion of the second major surface of the first sheet of glass.
The second sheet of glass may be provided at any time prior to being positioned on the interlayer structure.
In some embodiments where the interlayer structure comprises a sheet of support material between the first sheet of adhesive interlayer material and a second sheet of adhesive interlayer material, and where following step (ii) the spacer is in direct contact with the second portion of the sheet of support material, it is preferred that the spacer has a pattern in or on the first major surface of the spacer. In such embodiments, during step (iii) the pattern in or on the first major surface of the spacer is transferred to the sheet of support material and/or the second sheet of adhesive interlayer material. The pattern may be transferred by pressing the first major surface of the spacer having the pattern therein or thereon, against the sheet of support material during step (iii).
In some embodiments the spacer is configured to nest on or with the second portion of the second major surface of the first sheet of glass.
In some embodiments, after step (ii) and before step (iii) a first mould is provided for pressing against the second sheet of glass and/or the spacer during step (iii).
Preferably the first mould is used to cold form the second sheet of glass during step (iii).
Preferably the first mould has a shape substantially the same as a shape of the first sheet of glass.
Preferably the first mould is a sheet of glass.
When a first mould is used, the first mould is removed from the surface of the second sheet of glass and/or the spacer following step (iii). In some embodiments, after step (ii) and before step (iii) a mould is provided for pressing against the first sheet of glass during step (iii). In such embodiments the mould is used to press the interlayer structure against the second sheet of glass during step (iii).
In some embodiments the spacer comprises a plastic material. Preferably the spacer comprises polyethylene terephthalate, polyethylene, polyvinyl chloride, polypropylene, polystyrene, polylactic acid, polycarbonate, acrylic, acrylonitrile butadiene styrene, nylon or polyoxymethylene.
In some embodiments the spacer comprises a rubber material. The rubber may be a natural rubber or a synthetic rubber. Preferably spacer comprises chlorosulfonated polyethylene (CSM), ethylene propylene diene monomer (EPDM), fluoroelastomers (FKM), polychloroprene (CR), silicone rubber (SiR) or styrene butadiene rubber (SBR).
In some embodiments, prior to step (iii) the first glass sheet has a curvature in at least one direction, and the second sheet of glass is flat, or substantially flat, or has less curvature than the first sheet of glass.
Preferably the following step (iv), the laminated glazing has a curvature defined by the curvature of the first sheet of glass.
In such embodiments the second sheet of glass is cold formed to a curvature defined essentially by the curvature of the first sheet of glass. A mould may be used to press against the second sheet of glass to cold form the second sheet of glass during step (iii).
In some embodiments the first sheet of adhesive interlayer material is coextensive with the first sheet of glass.
Other embodiments of the first aspect of the present invention have other preferable features.
Preferably the first sheet of adhesive interlayer material comprises polyvinyl butyral (PVB), acoustic modified PVB, a copolymer of ethylene such as ethylene vinyl acetate (EVA), polyurethane (PU) or poly vinyl chloride (PVC).
Preferably the first sheet of adhesive interlayer material has a thickness between 0.3mm and 2.3mm, more preferably between 0.3mm and 1.6mm, even more preferably between 0.3mm and 0.9mm.
Preferably the first sheet of glass has a thickness between 1.0mm and 10mm, more preferably between 1.4mm and 6.0mm, even more preferably between 1.4mm and 3.0mm.
Preferably the first sheet of glass is a coated sheet, there being a coating on the first and/or second major surface of the first sheet of glass. The coating on the first and/or second major surface of the first sheet of glass may be a low emissivity coating or a solar control coating. Such coatings are known in the art and may comprise one or more layer of silver.
Preferably the second sheet of glass is a coated sheet, there being a coating on the first and/or second major surface of the first sheet of glass. The coating on the first and/or second major surface of the second sheet of glass may be a low emissivity coating or a solar control coating. Such coatings are known in the art and may comprise one or more layer of silver.
Preferably the first sheet of glass is a sheet of float glass.
Preferably the first sheet of glass is a sheet of soda-lime-silicate glass.
Preferably the first sheet of glass has soda-lime-silicate glass composition comprising (by weight), Si02 69- 74 %; A1203 0 - 3 %; Na20 10 - 16 %; K20 0 - 5 %; MgO 0 - 6 %; CaO 5 - 14 %; S03 0 - 2%.
Preferably the first sheet of glass has a soda-lime-silicate glass composition comprising (by weight), Si02 69 - 74 %; A1203 0 - 3 %; Na20 10 - 16 %; K20 0 - 5 %; MgO 0 - 6 %; CaO 5 - 14 %; S03 0 - 2 % and Fe203 0.005 - 2 %.
Preferably the first sheet of glass is a sheet of thermally toughened glass or thermally semi- toughened glass.
Preferably the first sheet of glass has a thickness between 1.3mm and 1.49mm and a surface compressive stress in at least a central region of the first major surface of the first sheet of glass sheet in the range of 18MPa to 23MPa.
Preferably the first sheet of glass has a thickness between 1.5mm and 1.69mm and a surface compressive stress in at least a central region of the first major surface of the first sheet of glass in the range of 23.1 MPa to 26MPa.
Preferably the first sheet of glass has a thickness between 1.7mm and 1.99mm and a surface compressive stress in at least a central region of the first major surface of the first sheet of glass in the range of 26.1 MPa to 30MPa.
Preferably the first sheet of glass has a thickness between 2.0mm and 2.19mm and a surface compressive stress in at least a central region of the first major surface of the first sheet of glass in the range of 30.1MPato 35MPa.
Preferably the first sheet of glass has a thickness between 2.2mm and 2.49mm and a surface compressive stress in at least a central region of the first major surface of the first sheet of glass in the range of 35.1MPato 45MPa. Preferably the first sheet of glass has a thickness between 2.5mm and 2.7mm and a surface compressive stress in at least a central region of the first major surface of the first sheet of glass in the range of45.1MPato 65MPa.
Preferably the first sheet of glass has a thickness between 2.71mm and 6mm and a surface compressive stress in at least a central region of the first major surface of the first sheet of glass in the range of 65.1 MPa to 150MPa, more preferably in the range of 65.1 MPa to lOOMPa.
Preferably the thickness of the second sheet of glass is less than 1.0mm, preferably less than 0.8mm.
Preferably the thickness of the second sheet of glass is greater than 0.3mm.
Preferably the thickness of the second sheet of glass is between 0.3mm and 1.0mm.
Preferably the thickness of the second sheet of glass is between 0.3mm and 0.8mm.
Preferably the second sheet of glass has been chemically strengthened.
Preferably the second sheet of glass is an alkali aluminosilicate glass composition.
Preferably the second sheet of glass includes at least about 6wt% aluminium oxide.
Preferably the second sheet of glass has a composition comprising 66-72 mol. % S1O2, 1-4 mol. % AI2O3, 8-15 mol. % MgO, 1-8 mol. % CaO, 12-16 mol.% Na20, preferably wherein MgO + CaO is between 12 and 17 mol. % and CaO/(MgO + CaO) is in the range 0.1 and 0.4.
Preferably the second sheet of glass has a composition comprising (by weight) 58% to 70% S1O2, 5% to 15% AI2O3, 12% to 18% Na20, 0.1% to 5% K20, 4% to 10% MgO and 0% to 1% CaO with the provisos that the sum of the AI2O3 and MgO exceeds 13%, that the sum of the amounts of AI2O3 plus MgO divided by the amount of K2O exceeds 3 and that the sum of the Na20 plus K2O plus MgO exceeds 22%.
Preferably the second sheet of glass is chemically strengthened to have a surface compressive stress greater than 400MPa, preferably between 400MPa and 900MPa, more preferably between 400MPa and 700MPa, even more preferably between 450MPa and 675MPa.
Preferably the second sheet of glass is chemically strengthened to have a surface compressive stress of around 900MPa or less.
Preferably the second sheet of glass is chemically strengthened to have a depth of layer (DOL) between 10 pm and 60pm, more preferably between 25pm and 45pm, even more preferably between 30pm and 40pm. Preferably the spacer has a uniform thickness defined by the separation of the first and second major surfaces of the spacer.
Preferably the method according to the first aspect of the present invention is used to make a laminated vehicle window, in particular a laminated vehicle side window.
From another aspect the present invention provides a vehicle having an aperture for a window, in particular a side window, wherein a laminated glazing made according to the first aspect of the present invention is movable or fixed within the aperture.
In some embodiments the laminated glazing made according to the first aspect of the present invention is configured such that the first and/or second sheet of glass comprises a respective first connection portion for connecting the laminated glazing to a mechanism for moving the laminated glazing, preferably in a vertical direction, and the laminated glazing is movable in the aperture in the vehicle by means of the mechanism connected to the first connection portion of the first or second sheet of glass.
Preferably the laminated glazing is vertically movable in the aperture.
Suitably the vehicle has an interior and the aperture has a periphery, wherein the laminated glazing is movable to a first position to close the aperture such that from the outside of the vehicle, the interior of the vehicle is not accessible via the aperture, and when the laminated glazing is in the first position there is a portion of the laminated glazing not facing the aperture and a portion of the second major surface of the first sheet of glass is not directly facing the first major surface of the second sheet of glass.
The present invention will now be described with reference to the following figures (not to scale) in which:
Figure 1 is a schematic plan view of a vehicle side window made in accordance with the first aspect of the present invention;
Figure 2 is a schematic cross-sectional representation of the vehicle side window shown in figure 1;
Figure 3-6 are schematic side views of a vehicle having a vehicle side window;
Figure 7 is a schematic cross-sectional exploded representation of the vehicle side window shown in figure 2;
Figure 8a is a schematic cross-sectional representation of a stack of unlaminated component parts used to make the laminated glazing shown in figure 1 ;
Figure 8b is a schematic cross-sectional representation of a stack of unlaminated component parts used to make a laminated glazing similar to that shown in figure 1 ; Figure 8c is a schematic plan-view of a portion of the unlaminated stack of components of figure 8b;
Figure 9 is a schematic isometric representation of the component parts used to make the laminated glazing 1;
Figure 10 is a schematic cross-sectional representation of a stack of unlaminated component parts used to make another laminated glazing in accordance with the present invention;
Figure 11 is a schematic cross-sectional representation of the stack of unlaminated component parts shown in figure 10 prior to being laminated together; and
Figure 12 is a schematic cross-sectional representation of the laminated glazing made in accordance with the present invention with reference to figures 10 and 11.
It is known in the art that surface compressive stress measurements of non-chemically strengthened glass (i.e. thermally toughened or strengthened soda-lime-silicate glass) may be made using a Strainoptics Laser GASP-CS (http://www.strainoptics.com/files/Laser%20GASP-CS%20Quick- Start%20(English).pdf). Such equipment is available from Strainoptics, Inc., 108 W. Montgomery Avenue, North Wales, PA 19454 USA. For high levels of surface compressive stress, as typically found in chemically strengthened glass and fully thermally toughened soda-lime-silicate glass, it is known in the art that a differential stress refractometer (DSR) may be used to measure surface compressive stress. Such equipment is available from Gaertner Scientific Corporation, 3650 Jarvis Avenue, Skokie, Illinois 60076 USA.
Figure 1 shows a plan view of a vehicle side window 1 made using a method in accordance with the present invention. In plan view, the vehicle side window 1 has an upper region 3, a lower region 5 and a connection region 7.
The upper region 3 is defined in relation to a line x-x’, and the line x-x’ is defined by the styling of the vehicle into which the vehicle side window is installed, as will be discussed in more detail below. In this example the connection region 7 comprises a first trapezoidal portion 7a and a second trapezoidal portion 7b. Each trapezoidal portion 7a, 7b has a respective hole 7c, 7d at the narrow end thereof. The holes 7c, 7d are used to connect a winder mechanism (not shown) to the vehicle side window 1 to move the vehicle side window vertically, i.e. in the direction of arrow 8.
The vehicle side window 1 has a major surface 10 configured for use as an outer surface. The major surface 10 has a central region 12, the central region being inboard of the periphery of the vehicle side window 1. Figure 2 shows a schematic cross-sectional representation of the laminated glazing 1 taken along the line y-y’ in figure 1.
The line x’-x” forms a horizontal plane with the line x-x\ The regions 3, 5 and 7 are defined in the same way as with reference to figure 1.
As can be seen from figure 2, the laminated glazing 1 has a first sheet of glass 14 joined to a second sheet of glass 15 by means of interlayer structure 16. The first sheet of glass 14 has a first major surface 14a and a second opposing major surface (not labelled in this figure). The second sheet of glass 15 has a first major surface (not labelled in this figure) and a second opposing major surface 15b.
The interlayer structure 16 consists of a first sheet of PVB 17 having a thickness of 0.76mm, a second sheet of PVB 18 having athickness of 0.76mm and a sheet of PET 19 having athickness of 400pm. Each of the first and second sheets of PVB 17, 18 have a respective first major surface and opposing second major surface. The sheet of PET 19 also has a first major surface and a second opposing major surface (labelled as 19b). The sheet of PET 19 is a sheet of support material and is between the first and second sheets of PVB 17, 18. In the event of breakage of the first sheet of glass 14, the first and second sheets of PVB 17, 18 remained adhered to the sheet of PET 19 so that the second sheet of glass 15 does not become detached from the laminated glazing 1. The sheet of PET 19 may have a solar control coating on at least a portion of a major surface thereof (i.e. major surface 19a and/or 19b - see figure 7).
The second sheet of PVB 18 is coextensive with the first sheet of glass 14. The second sheet of PVB 18 may be slightly inboard the edge of the first sheet of glass 14, especially in the upper region 3.
The sheet of PET 19 is coextensive with the second sheet of PVB 18 and may be part of a composite structure, for example the sheet of PVB 18 may be joined to the sheet of PET 19 prior to laminating the first sheet of glass 14 to the second sheet of glass 15 by means of the interlayer structure 16. That is, the sheet of PET 19 may be j oined to the sheet of PVB 18 in the form of a composite structure of the type used for spall protection.
The exposed portion of the major surface 19b of the sheet of PET 19 may have an anti -abrasion hard coat or a solar control coating thereon. Prior to being incorporated into the laminated glazing 1, such a coating (i.e. anti-abrasion or solar control) may extend over the entire exposed major surface of the sheet of PET 19. In such an example, the first sheet of PVB 17 would be in direct contact with the coating instead of being in direct contact with the sheet of PET 19.
The first sheet of PVB 17 is coextensive with the second sheet of glass 15. However, the first sheet of PVB 17 and the second sheet of glass 15 are not coextensive with the first sheet of glass 14. The first sheet of glass 14 is a sheet of soda-lime-silicate glass having a composition such as clear float glass, typically with the addition of iron oxide as a tinting agent to provide the laminated glazing with some form of solar control. The first sheet of glass may have a different composition, such as a borosilicate glass composition or an aluminosilicate glass composition.
In this example the first sheet of glass 14 has a thickness of 4.85 mm and has been thermally toughened using a conventional high pressure cooling air technique such that the compressive stress in at least the central region 12 of the first sheet of glass 14 is around 90 MPa.
The second sheet of glass 15 has a thickness of 0.6 mm but may have a thickness in the range of 0.3 mm to 0.8 mm, for example 0.4 mm to 0.8 mm. The second sheet of glass 15 may have a thickness of 0.55mm or 0.7mm.
The second sheet of glass 15 has been chemically strengthened using a conventional molten salt ion exchange process to exchange sodium ions in the surface of the second sheet of glass with potassium ions from a suitable molten salt. The chemical strengthening process is controlled to provide the second sheet of glass with a depth of layer (DOL) of 35 pm and a surface compressive stress greater than 400MPa, typically between 450MPa and 700MPa. The surface compressive stress may be as high as 900MPa. The DOL may be between 30pm and 40pm.
A specific composition for the second sheet of glass 15 is 68 mol% S1O2, 2.5 mol% AI2O3, 11 mol% MgO, 3.7 mol% CaO, 14.2 mol% Na20, 0.6 mol% K2O. For this composition MgO + CaO is 14.7 mol% and Na20 + K2O is 14.8 mol%. This is composition number 13 in table 2 on page 20 of W02014/148020A1 as published. The iron oxide (Fe203) content of the second sheet of glass may be low, being less than 0.1 percent by weight i.e. about 0.012 percent by weight.
As shown in figure 2, hole 7d passes through the first sheet of glass 14, the second sheet of PVB 18 and the sheet of PET 19.
As figure 2 shows, part of the interlayer structure 16 extends below the line x’ -x” , and consequently below the line x-x’ in figure 1.
As discussed above, the second sheet of PVB 18 is coextensive with both the sheet of PET 19 and the first sheet of glass 14 (other than at the hole 7d). As such, the second sheet of PVB 18 and the sheet of PET 19 extend below the line x’-x” (and x’-x’ in figure 1) to cover the lower region 5, which includes the connection region 7. The region of the hole 7d is also surrounded by PVB (from the second sheet of PVB 18) and PET (from the sheet of PET 19).
In an alternative embodiment to that shown, the hole 7d is still surrounded by PVB and PET but either or both the second sheet of PVB 18 and the sheet of PET 19 are not coextensive with the first sheet of glass 14. For example, the second sheet of PVB 18 may extend slightly below the hole 7d, or the second sheet of PVB may be coextensive with the first sheet of glass 14 whereas the sheet of PET 19 may extend below the line x’-x” but may not be coextensive with the second sheet of PVB 18.
In accordance with the present invention, the laminated glazing 1 has a first region 2 and a second region 6. The first region 2 is essentially that part of the laminated glazing 1 where a portion of the interlayer structure 16 is between the first sheet of glass 14 and the second sheet of glass 15. In the second region 6, the first sheet of PVB 17 does not cover a portion of the second major surface of the first glass sheet 14.
As is evident from figures 1 and 2, the first region 2 includes the upper region 3 because the first region 2 extends below the lines x’-x” and x-x \ The portion of the sheet of PET 19 not covered by the first sheet of PVB 17 and the second sheet of glass 15 may be used to define the second region 6 of the laminated glazing 1.
As can be seen from figure 2, the first region 2 of the laminated glazing 1 has in sequence a first portion of the first sheet of glass 14, a first portion of the second sheet of PVB 18, a first portion of the sheet of PET 19, the first sheet of PVB 17 and the second sheet of glass 15. Or put another way, a ray of light at normal incidence to the first major surface 14a of the first sheet of glass 14 in the first region 2 passes through the laminated glazing 1 by passing through, in sequence, the first sheet of glass 14, the second sheet of PVB 18, the PET sheet 19, the first sheet of PVB 17 and finally the second sheet of glass 15, to emerge from the second major surface 15b of the second sheet of glass 15.
The second region 6 of the laminated glazing 1 has in sequence a second portion of the first sheet of glass 14, a second portion of the second sheet of PVB 18 and a second portion of the sheet of PET 19, where the second portion of the sheet of PET 19 has an exposed portion of the second major surface 19b of the sheet of PET 19. The exposed portion of the second major surface 19b of the sheet of PET 19 does not face the first sheet of glass 14 but faces away from the first sheet of glass 14. The exposed portion of the second major surface 19b of the sheet of PET 19 is not covered by the first sheet of PVB 17 or the second sheet of glass 15.
The first region 2 includes the upper region 3 and it is important to have good optical quality in the upper region 3 (and the majority of the first region 2) because in use, this part of the laminated glazing is a through vision region of the laminated glazing i.e. is used for a person to see through.
As is evident from figures 1 and 2, the second region 6 is part of the lower region 5, and in use is not a through vision region so the transmission of visible light in this region is less important. However, it has been found due to the uneven thickness of the interlayer structure over the first sheet of glass 14, the optical quality in the first region 2 may be affected due to the lamination method used to produce the laminated glazing 1.
Figure 3 shows a schematic side view of a vehicle 50 (i.e. a car). The vehicle 50 has a side door 52 and an aperture 54 having a periphery 56 in which a vehicle side window of the type shown in figures 1 and 2 is vertically movable therein in a manner known in the art. The periphery 56 may be defined by part of the vehicle door i.e. a suitable frame, or a part of the vehicle body.
The periphery 56 has comers j, k and m. The line j-m defines the position of the line x-x’ shown in figure 1. In figure 3 the aperture 54 is shown in a closed configuration with the vehicle side window closing the aperture 54. With reference to figures 1 and 2, a portion of the major surface 10 of the first sheet of glass closes the aperture 54.
Also shown in figure 3, the vehicle 50 has a fixed side window 58 that may be made in accordance with the present invention. However, as the side window 58 is fixed in a frame, there is no need for the side window 58 to have a connection region for connecting a winder mechanism to the side window 58.
Figure 4 shows the vehicle 50 with the aperture 54’ in a second configuration with the vehicle side window wound fully down.
With reference to figures 1-3, figure 5 shows vehicle 50 having a side door 52 incorporating a vehicle side window 1 movable in aperture 54. In this figure, the vehicle side window 1 below the line x-x’ (i.e. the line j-m defined by the aperture) is shown in phantom. Located in a lower portion of the door 52 is a winder mechanism 60. A suitable linkage 62 connects the winder mechanism 60 to the connection region of the vehicle side window 1. A first linkage member 63 is in mechanical communication with the first trapezoidal portion 7a and a second linkage member 64 is in mechanical communication with the second trapezoidal portion 7b. The holes 7c, 7d may be used to attach an end of the respective linkage member 63, 64 to the respective trapezoidal portion 7a, 7b. The linkage member 63, 64 may be configured at one end thereof to pass through the respective hole and be secured to the first sheet of glass 14 by a clamping mechanism across the major surfaces thereof.
The aperture 54 is closed by the upper region 3 of the vehicle side window 1.
Figure 6 shows the vehicle 50 shown in figure 5 where the winder mechanism 60 has been suitably actuated to wind the vehicle side window partially down such that there is an opening 66 in the aperture 54 i.e. the aperture is no longer fully closed. By actuation of the winder mechanism 60 the winder linkage 62 moves from the first position shown in figure 5 to the second position shown in figure 6. Each of the first and second linkages 63, 64 are suitably moved towards the winder mechanism 60 thereby lowering the vehicle side window in the aperture. Consequently, the line x-x’ on the vehicle side window 1 moves below the line j-m defined by the aperture 54. The interior of the vehicle 50 is accessible via the opening 66.
Figure 7 is an exploded cross-sectional schematic view of the laminated glazing 1 shown in figure 2, but in a horizontal arrangement. Figure 7 is illustrative of the individual components used to make up the laminated glazing 1 prior to the lamination method.
As more clearly seen in figure 7, the first sheet of glass 14 has a first major surface 14a and a second opposing major surface 14b. The second sheet of glass 15 has a first major surface 15a and a second opposing major surface 15b. The second major surface 14b of the first sheet of glass 14 faces the first major surface 15a of the second sheet of glass 15.
The first sheet of PVB 17 has a first major surface 17a and a second opposing major surface 17b. The sheet of PET 19 has a first major surface 19a and a second opposing major surface 19b. The second sheet of PVB 18 has a first major surface 18a and a second opposing major surface 18b.
Each of the first sheet of glass 14, the second sheet of PVB 18 and the sheet of PET 19 have a respective hole 14d, 18d, 19d therein, and the holes 14d, 18d, 19d align in the laminated glazing 1 to form hole 7d. In this example the holes 14d, 18d, 19d are all circular but they may have other shapes. Also, in this example the holes 14d, 18d, 19d all have the same diameter. The hole 18d is an opening in the second sheet of PVB 18. The hole 19d is an opening in the sheet of PET 19.
In the second region 6 a portion of the second major surface 14b of the first sheet of glass 14 is not covered by the first sheet of PVB 17.
With reference to figures 7, 8a and 9, to produce the laminated glazing 1, the first sheet of glass 14 is initially placed onto a suitable support such that the second major surface 14b of the first sheet of glass faces upwards.
Next, the second sheet of PVB 18 is placed onto the first sheet of glass 14 such that the second major surface 18b faces upwards and the hole 18d is aligned with the hole 14d in the first sheet of glass. The periphery of the second sheet of PVB 18 is aligned with the periphery of the first sheet of glass 14 i.e. the second sheet of PVB 18 is congruently stacked on the first sheet of glass 14. Alternatively, and with reference to figure 9, an over-sized sheet of PVB 28 may be used instead of a pre-cut sheet of PVB 18. The over-sized sheet of PVB 28 is positioned on the first sheet of glass 14 and cut to size by trimming off the excess PVB 28’ using the periphery of the first sheet of glass 14 as a template.
Next, a sheet of PET 19 is placed on the second sheet of PVB 18 such that the hole 19d therein is aligned with the hole 18d and the second major surface 19b faces upwards. The periphery of the sheet of PET 19 is aligned with the periphery of the second sheet of PVB 18 i.e. the first sheet of glass 14, the second sheet of PVB 18 and the sheet of PET 19 are congruently stacked. Alternatively, and again with reference to figure 9, an over-sized sheet of PET 29 may be used instead of a pre-cut sheet of PET 19. The over-sized sheet of PET 27 is positioned on the first sheet of PVB 17 and cut to size by trimming off the excess PET 29’ using the periphery of the first sheet of glass 14 with first sheet of PVB thereon as a template.
Next the first sheet of PVB 17 is placed on the second major surface 19b such that the second major surface 17b faces upwards. Three sides of the periphery of the first sheet of PVB 17 are aligned with portions of the periphery of the sheet of PET 19.
Finally, the second sheet of glass 15 is positioned on the first sheet of PVB 17. The periphery of the second sheet of glass 15 is aligned with the periphery of the first sheet of PVB 17 i.e. the second sheet of glass 15 is congruently stacked with the first sheet of PVB 17. The first major surface 15a of the second sheet of glass 15 faces the second major surface 14b of the first sheet of glass 14.
In accordance with the present invention, a spacer 20 is positioned on the exposed part of the PET (the portion of the PET sheet 19 not covered by the first sheet of PVB 17 and the second glass sheet 15). As shown in figure 8, the spacer 20 is moved in the direction of arrow 22 onto the exposed portion of the second major surface 19b of the sheet of PET 19.
In this example the spacer 20 was made of polycarbonate although other plastic material may be used. The spacer 20 may be made of a synthetic rubber material, for example EPDM.
The spacer 20 has a first major surface 20a and a second opposing major surface 20b. The shape of the major surface 20a is configured to nest with the sheet of PET 19 on the second sheet of PVB 18 and the first sheet of glass 14 in the second region 6. The second sheet of PVB 18 and the sheet of PET 19 each have major surfaces that are parallel to each other. Accordingly, the shape of the major surface 20a is configured to nest with the first sheet of glass 14 in the second region 6.
The thickness of the spacer 20 is substantially the same as the combined thickness of the second sheet of glass 15 and the first sheet of PVB 17. For example, if the first sheet of PVB 17 has a thickness of 0.38mm and the second sheet of glass 15 has a thickness of 0.7mm, the spacer preferably has a thickness of 1.08mm. The second major surface 20b of the spacer 20 is aligned with the second major surface 15b of the second sheet of glass 15 when positioned on the exposed portion of the sheet of PET 19. If additional glass/PVB sheets are on the second sheet of glass 15 the spacer preferably has a thickness the same, or substantially the same, as a combined thickness of all said sheets of PVB/glass, which includes the first sheet of PVB 17 and the second sheet of glass 15. The spacer is used to avoid a step between the second major surface 15b of the second sheet of glass 15 (which is an exposed inner or outer pane of the laminated glazing) and the second major surface 19b of the sheet of PET 19. The periphery of the spacer 20 may be aligned with the periphery of the sheet of PET 19 in the second region 6. In an alternative, and with reference to figure 9, the spacer 20 may be replaced by a spacer 201. The spacer 201 has a similar periphery to the spacer 20 but is not aligned with the spacer between the two trapezoidal portions 7a and 7b. In another alternative, a spacer 202 may be used which has a rectangular outline periphery.
A minor face 20’ of the spacer 20 is adjacent the minor faces 17’ and 15’ of the first sheet of PVB 17 and the second sheet of glass 15 respectively. The minor face 20’ of the spacer may directly contact the minor face 15’ of the second sheet of glass 15 and/or the minor face 17’ of the first sheet of PVB 17. It is preferred for there to be a gap between the minor faces 15 ’ and 17’ and the minor face 20’ i.e. the spacer 20 is spaced apart from the first sheet of PVB 17 and the second sheet of glass 15 when the spacer 20 is on the exposed portion of the second major surface 19b of the sheet of PET 19. By having such a gap, it is easier to de-air the unlaminated stack during lamination.
In an alternative embodiment to that shown in figure 8a, the spacer 20 may have a portion extending from the first major surface 20a thereof for extending into the hole 7d when the spacer is positioned on the exposed portion of the PET 19. This may help locate the spacer 20 in the preferred position on the exposed portion of the PET 19. The provision of such a portion extending from the first major surface 20a of the spacer 20 may also act as a barrier to prevent interlayer material from the second sheet of adhesive interlayer material flowing into hole 7d.
Back to the embodiment shown in figure 8a, with the spacer 20 on the exposed portion of the second major surface 19b of the sheet of PET 19, a mould 23 is then positioned on the second sheet of glass 15 and the spacer 20 by moving the mould 23 in the direction of arrow 24. In this example the mould is a glass sheet having smooth major surfaces. Other material that is dimensionally stable during the lamination process may be used for the mould, for example stainless steel. The mould 23 is preferably made of a material that does not adhere to the second sheet of glass 15 or the spacer 20. In this example the mould 23 does not adhere to the second major surface 15b of the second sheet of glass 15 or to the second major surface 20b of the spacer 20. The mould 23 is used to press against the second sheet of glass 15 and spacer 20 especially during the lamination process.
The entire assembly of first sheet of glass 14, second sheet of PVB 18, sheet of PET 19, first sheet of PVB 17 and second sheet of glass 15 prior to lamination (with or without the spacer 20 and/or mould 23) may be referred to as an unlaminated stack.
The unlaminated stack including the spacer and mould in position as described above is then laminated at a temperature in the range 90 °C to 140 °C and a pressure in the range 8 bar to 16 bar. Lamination is possible at a higher temperature, but this is not desirable due to potentially affecting the optical quality in the first region 2 and/or the increased energy usage required to produce the laminated glazing.
After lamination, the mould 23 may be removed from the second sheet of glass 15 and the spacer 20 because the mould does not adhere thereto during the lamination process. The spacer 20 may be removed from the exposed portion of the second major surface 19b of the sheet of PET 19 because the spacer 20 does not adhere thereto. A spacer that includes a releasable adhesive layer may be used in the present invention but is less preferred as such a spacer may be more difficult to remove from the exposed portion of the second major surface 19b of the sheet of PET 19 following lamination.
In a comparative test, a laminated glazing as described above and with reference to figures 1, 2 and 7 was made except no spacer 20 or mould 23 were used during the lamination step. It was found that the optical quality of the laminated glazing in the first region was not as high compared to using the spacer as outlined above. The optical quality was assessed using methods known in the art, such as described in W02004/083835A1 or US5,694,479.
In a modification to the above described method, in addition to a mould 23 being used to press against the second sheet of glass 15 and the spacer 20, another mould is used to press against the first sheet of glass 14. This additional mould is shown in figure 9 in phantom and is labelled 231. The mould 231 may be used to press against the first major surface 14a of the first sheet of glass 14 during lamination, and the unlaminated stack may be laid up on the mould 231 prior to the mould 23 being included. The mould 231 may be made of the same material as the mould 23 and may have a shape configured for the first sheet of glass 14 to nest therein.
In an alternative example, the spacer 20 has a pattern on the first major surface 20a. It was found that upon pressing the spacer 20 against the exposed portion of the second major surface 19b of the sheet of PET 19 (i.e. the first major surface 20a of the spacer being in contact with the exposed portion of the second major surface 19b of the sheet of PET 19), the pattern on the first major surface 20a of the spacer 20 was transferred to the portion of the interlayer structure in the second region 6. The pattern on the first maj or surface 20a was transferred to the sheet of PET 19 and/or the second sheet of PVB 18 in the second region 6.
The pattern on the first major surface 20a of the spacer 20 may also, or instead of, be in the first major surface 20a. Using such a patterned spacer provides a method for providing the laminated glazing 1 with a pattern in the second region. Such a pattern may be in the form of text and/or a picture.
In another alternative example further illustrated additionally by figures 8b and 8c, the hole 18d in the second sheet of PVB 18 and the hole 19d in the sheet of PET 19 have a larger diameter than the hole 14d in the first sheet of glass 14. In such an example, it is preferred that both the holes 18d and 19d have the same diameter. It is also preferred that the centre of the holes 18d, 19d and the hole 14d in the first sheet of glass 14 are all aligned to create a through hole 7d\ By having the diameter of the holes 18d, 19d to be larger than the diameter of hole 14d, a portion of the second major surface 14b of the first sheet of glass 14 is accessible through the holes 18d, 19d. This portion of the second major surface 14b is labelled 14b* in figure 8b and figure 8c. Figure 8c is a view of the laminated glazing G in the direction of arrow 22. In this example, a linkage member may be attached to the first sheet of glass 14 by passing through the hole 7d’ and clamping across portions of the first major surface 14a and second major surface 14b (i.e. portion 14b*) adjacent the ends of the hole 14d.
Instead of circular holes 18d, 19d, other configuration of void in the first sheet of PVB 18 and sheet of PET 19 may be provided (i.e. square, rectangular, triangular, multi-sided) instead to allow access to a portion of the second major surface 14b of the first sheet of glass adjacent the end of the hole 14d in the second major surface 14b. Provision of such voids in the first sheet of PVB 18 and sheet of PET 19 allow a linkage member to be attached to the first sheet of glass 14 by passing through the hole 14d and clamping across portions of the first and second major surfaces 14a, 14b adjacent the ends of the hole 14d.
If the holes 18d, 19d are sized such that the second major surface 14b is accessible, the spacer may be configured with a portion extending from the first major surface 20a thereof to fit in the holes 18d, 19d preferably to contact the second major surface 14b when the spacer is positioned on the exposed part of the sheet of PET 19. In figure 8b such a spacer is labelled 20” and has a first major surface 20a’, a second major surface 20b’ and a portion 20c’ extending from the first major surface 20a’. The first major surface 20b’ is substantially flat. The portion 20c’ has a flat region 20d’ at an end thereof.
It is preferred that the spacer 20” is configured such that the portion 20c’ nests with the hole 18d and/or 19d. In such embodiments, the spacer 20” does not have a uniform thickness but is still configured such that the second major surface 20b’ aligns with the second major surface 15b of the second sheet of glass 15. For example, if the thickness of the second sheet of PVB 18 is 0.76mm and the thickness of the sheet of PET 19 is 0.04mm, the portion 20c’ of the spacer extending away from the first major surface 20a’ may extend up to 0.80mm from the first major surface 20a’. In this configuration the first major surface 20a’ of the spacer 20” can rest on the exposed portion of the sheet of PET 19 and the flat region 20’ can rest on the portion 14b* of the second major surface 14b. The separation between the first and second major surfaces 20a’, 20b’ of such a spacer 20” would be substantially the same as the combined thickness of the second sheet of glass 15 and the first sheet of PVB 17 so that the second major surface 20b’ is aligned, or substantially aligned with the second major surface 15 of the second sheet of glass 15.
The provision of such a portion 20c’ extending from the first major surface 20a’ of the spacer 20” may also assist with aligning the spacer 20” on the exposed portion of the sheet of PET 19 because said portion 20c’ essentially acts as a locating pin with the opening in the sheet of support material and the opening in the second sheet of adhesive interlayer material.
The provision of such a portion 20c’ extending from the first major surface 20a’ of the spacer 20” may also act as a barrier to prevent material from the second sheet of adhesive interlayer material 18 flowing into hole 7d’.
Although in the previous figures the vehicle side window 1 is shown as being flat (or planar) having a flat outer surface, the vehicle side window 1 may be curved in one or more directions. The radius of curvature in one of the one or more directions may be between 1000mm and 8000mm. When the laminated glazing is curved in two directions, suitably each direction of curvature is orthogonal to the other. Suitably the radius of curvature in one or both directions of curvature is between 1000mm and 8000mm.
Suitable techniques are known for shaping the first sheet of glass i.e. gravity sag bending, press bending etc. However, the second sheet of glass may be initially flat and “cold formed” to the desired shape set by the curved first sheet of glass by applying suitable pressure to the flat second sheet of glass during the lamination process. The temperature during the lamination process is sufficient to cause to the adhesive layer (i.e. a sheet of PVB) to bond to the first and second sheets of glass, but such temperature is not sufficient to cause the second sheet of glass alone to be deformed by pressing between complementary shaping members and/or sagging under the influence of gravity.
When the first sheet of glass is curved, the spacer may be curved to nest with the first sheet of glass in the second region of the resulting laminated glass, or the spacer may be shaped differently and have a curvature imposed thereon by the first sheet of glass and suitable mould 23.
Figure 10 shows a schematic exploded cross-sectional view of another laminated glazing 100 made in accordance with the present invention.
The laminated glazing 100 comprises a first sheet of glass 114 joined to a second sheet of glass 115 by means of a sheet of EVA 117. The first sheet of glass 114 has a first major surface 114a and a second opposing major surface 114b. The sheet of EVA 117 has a first major surface 117a and a second opposing major surface 117b. The second sheet of glass 115 has a first major surface 115a and a second opposing major surface 115b.
The laminated glazing 110 is arranged such that the second major surface 114b of the first sheet of glass 114 faces the first major surface 117a of the sheet of EVA 117. The second major surface 117b of the sheet of EVA 117 faces the first major surface 115a of the second sheet of glass 115. Consequently, the second major surface 114b of the first sheet of glass 114 faces the first major surface 115a of the second sheet of glass 115. The sheet of EVA 117 is coextensive with the second sheet of glass 115. Three edges of the sheet of EVA 117 and the second sheet of glass 115 are aligned with portions of three edges of the first sheet of glass 114.
The laminated glazing 100 has two region 102, 106. The first region 102 includes the sheet of EVA 117 between the second sheet of glass 115 and a portion of the first sheet of glass 114. In the second region 106 the sheet of EVA 117 and the second sheet of glass 115 do not cover the first sheet of glass 114.
In accordance with the present invention, the laminated glazing 100 is made as follows and with reference to figures 10, 11 and 12.
Firstly, a mould 31 is positioned on a flat surface. Next, the first sheet of glass 114 is position on the mould 31 such that the second major surface 114b faces upwards.
The sheet of EVA 117 is positioned on the first sheet of glass 114 such that a first portion of the second major surface 114b is covered by the sheet of EVA 117. A second portion of the second major surface 114b of the first sheet of glass 114 is not covered by the sheet of EVA 117.
Next the second sheet of glass is positioned on the sheet of EVA 117.
A plastic spacer 120 having first and second opposed major surfaces 120a, 120b is positioned on the second major surface 114b of the first sheet of glass 114 in the second region 106 i.e. in the direction of arrow 122. That is, the plastic spacer 120 is positioned on the second portion major of the second major surface 114b of the first sheet of glass 114.
Finally, a second mould 33 is positioned on the second sheet of glass 115 and the spacer 120.
The unlaminated stack including the spacer 120 and moulds 31, 33 is then subjected to a lamination process at a temperature in the range 80 °C to 110 °C and a pressure in the range 8 bar to 16 bar. During lamination, the first mould 31 presses against the first sheet of glass 114 in the direction of arrow 124 and the second mould 33 presses against the second sheet of glass 115 and the spacer 120 in the direction of arrow 126.
Following lamination, the moulds 31, 33 are removed and the spacer 120 is removed from the first sheet of glass 114 i.e. in direction of arrow 128.
Figure 12 also illustrates the slight gap 130 between the edge of the spacer 120 and the edges of the second sheet of glass 115 and the sheet of EVA 117. The gap 130 helps de-airing during lamination.
The present invention provides methods for making a laminated glazing comprising a first sheet of glass joined to a second sheet of glass by means of an interlayer structure therebetween. Prior to lamination, an unlaminated stack is formed where a first portion of a major surface of the first sheet of glass is covered by a portion of the interlayer structure and a second portion of the major surface of the first sheet of glass is not covered by the interlayer structure; the second sheet of glass is on the interlayer structure; and the spacer is on the second portion of the major surface of the first sheet of glass and is at least partially aligned with a major surface of the second sheet of glass not facing the interlayer structure. Following lamination, the spacer is removed from the laminated glazing.
The present invention finds particular application in the field of vehicle glazings, especially vehicle side windows that may be movable within an aperture in the vehicle or fixed in an aperture in the vehicle. The laminated glazings may be used in the rear of a vehicle (i.e. as part or all of a vehicle backlight) or in the roof of a vehicle. A laminated glazing made according to the present invention has improved optical quality in the aperture region of the glazing.

Claims

1. A method for making a laminated glazing comprising the steps:
(i) providing a first sheet of glass having a first major surface and a second opposing major surface, an interlayer structure comprising at least a first sheet of adhesive interlayer material, a second sheet of glass having a first major surface and a second opposing major surface and a spacer having a first major surface and a second opposing major surface;
(ii) positioning the interlayer structure, the spacer and the second sheet of glass on the second major surface of the first sheet of glass such that a first portion of the second major surface of the first sheet of glass is covered by at least a portion of the interlayer structure and a second portion of the second major surface of the first sheet of glass is not covered by the interlayer structure, the second sheet of glass is on the interlayer structure and the first major surface of the second sheet of glass faces the second major surface of the first sheet of glass, and the spacer is on the second portion of the second major surface of the first sheet of glass and the second major surface of the spacer is at least partially aligned with the second major surface of the second sheet of glass;
(iii) using suitable lamination conditions to laminate the first sheet of glass to the second sheet of glass via the interlayer structure; and
(iv) removing the spacer from the laminated glazing.
2. A method according to claim 1, wherein the interlayer structure is first positioned on the second major surface of the first sheet of glass, then the second sheet is glass positioned on the interlayer structure, and then the spacer is positioned on the second major surface of the first sheet of glass.
3. A method according to claim 2, comprising the steps:
(a) providing a first sheet of glass having a first major surface and a second opposing major surface;
(b) providing an interlayer structure, the interlayer structure comprising at least a first sheet of adhesive interlayer material; (c) positioning the interlayer structure on the second major surface of the first sheet of glass such that a first portion of the second major surface of the first sheet of glass is covered by at least a portion of the first sheet of adhesive interlayer material and a second portion of the second major surface of the first sheet of glass is not covered by the first sheet of adhesive interlayer material;
(d) providing a second sheet of glass having a first major surface and a second opposing major surface;
(e) positioning the second sheet of glass on the interlayer structure such that the first major surface of the second sheet of glass faces the second major surface of the first sheet of glass;
(f) providing a spacer having a first major surface and a second opposing major surface;
(g) positioning the spacer on the second portion of the second major surface of the first sheet of glass, the spacer being configured such that the second major surface of the spacer is at least partially aligned with the second major surface of the second sheet of glass when the spacer is on the second portion of the second major surface of the first sheet of glass and the first major surface of the spacer faces the second major surface of the first sheet of glass;
(h) using suitable lamination conditions to laminate the first sheet of glass to the second sheet of glass via the interlayer structure; and
(j) removing the spacer from the laminated glazing.
4. A method according to claim 1, wherein the interlayer structure is first positioned on the second major surface of the first sheet of glass, then the spacer is positioned on the second major surface of the first sheet of glass, and then the second sheet of glass positioned on the interlayer structure.
5. A method according to claim 4, comprising the steps:
(a) providing a first sheet of glass having a first major surface and a second opposing major surface;
(b) providing an interlayer structure, the interlayer structure comprising at least a first sheet of adhesive interlayer material; (c) positioning the interlayer structure on the second major surface of the first sheet of glass such that a first portion of the second major surface of the first sheet of glass is covered by at least a portion of the first sheet of adhesive interlayer material and a second portion of the second major surface of the first sheet of glass is not covered by the first sheet of adhesive interlayer material;
(d) providing a spacer having a first major surface and a second opposing major surface;
(e) positioning the spacer on the second portion of the second major surface of the first sheet of glass;
(f) providing a second sheet of glass having a first major surface and a second opposing major surface;
(g) positioning the second sheet of glass on the interlayer structure such that the first major surface of the second sheet of glass faces the second major surface of the first sheet of glass, the spacer being configured such that the second major surface of the spacer is at least partially aligned with the second major surface of the second sheet of glass when the spacer is on the second portion of the second major surface of the first sheet of glass and the first major surface of the spacer faces the second major surface of the first sheet of glass;
(h) using suitable lamination conditions to laminate the first sheet of glass to the second sheet of glass via the interlayer structure; and
(j) removing the spacer from the laminated glazing.
6. A method according to claim 1, wherein the spacer is first positioned on the second major surface of the first sheet of glass, then the interlayer structure is positioned on the second major surface of sheet of glass, and then the second sheet of glass positioned on the interlayer structure
7. A method according to claim 6, comprising the steps:
(a) providing a first sheet of glass having a first major surface and a second opposing major surface;
(b) providing a spacer having a first major surface and a second opposing major surface; (c) positioning the spacer on the second major surface of the first sheet of glass such that a first portion of the second major surface of the first sheet of glass is not covered by the spacer and a second portion of the second major surface of the first sheet of glass is covered by at least a portion of the spacer and the first major surface of the spacer faces the second major surface of the first sheet of glass;
(d) providing an interlayer structure, the interlayer structure comprising at least a first sheet of adhesive interlayer material;
(e) positioning the interlayer structure on the first portion of the second major surface of the first sheet of glass;
(f) providing a second sheet of glass having a first major surface and a second opposing major surface;
(g) positioning the second sheet of glass on the interlayer structure such that the first major surface of the second sheet of glass faces the second major surface of the first sheet of glass, the spacer being configured such that the second major surface of the spacer is at least partially aligned with the second major surface of the second sheet of glass when the second sheet of glass is positioned on the interlayer structure;
(h) using suitable lamination conditions to laminate the first sheet of glass to the second sheet of glass via the interlayer structure; and
(j) removing the spacer from the laminated glazing.
8. A method according to any of the preceding claims, wherein the interlayer structure comprises a second sheet of adhesive interlayer material and wherein following step (ii) the second sheet of adhesive interlayer material is between the first sheet of glass and the first sheet of adhesive interlayer material and the first sheet of adhesive interlayer material is between the second sheet of glass and the second sheet of adhesive interlayer material
9. A method according to claim 8, wherein the second sheet of adhesive interlayer material comprises polyvinyl butyral (PVB), acoustic modified PVB, polyurethane (PU) or a copolymer of ethylene such as ethylene vinyl acetate (EVA) and/or wherein the second sheet of adhesive interlayer material has a thickness between 0.3mm and 2.3mm, preferably between 0.3mm and 1.6mm, more preferably between 0.3mm and 0.9mm.
10 A method according to claim 8 or claim 9, wherein the entire second portion of the second major surface of the first sheet of glass is covered by at least a portion of the second sheet of adhesive interlayer material, preferably wherein the entire second major surface of the first sheet of glass is covered by at least a portion of the second sheet of adhesive interlayer material.
11. A method according to any of the claims 8 to 10, wherein the interlayer structure comprises a sheet of support material between the first sheet of adhesive interlayer material and the second sheet of adhesive interlayer material, preferably wherein the sheet of support material comprises a polyester, in particular polyethylene terephthalate (PET), or a sheet of glass or an ionoplast interlayer material.
12. A method according to claim 11, wherein the sheet of support material has a coating on at least a portion of a major surface thereof, preferably wherein the coating covers an entire major surface of the sheet of support material and/or wherein the coating comprises a solar control coating, in particular a solar control coating preferably comprising one or more layer of silver.
13. A method according to claim 11 or claim 12, wherein following step (ii), a first portion of the sheet of support material is between the first and second sheets of adhesive interlayer material and a second portion of the sheet of support material is not between the first and second sheets of interlayer material.
14. A method according to claim 13, wherein the entire second portion of the second major surface of the first sheet of glass is covered by at least a portion of the second portion of the sheet of support material, preferably wherein the entire second major surface of the first sheet of glass is covered by at least a portion of the sheet of support material.
15. A method according to claim 13 or claim 14, wherein following step (ii) the spacer is in direct contact with the second portion of the sheet of support material.
16. A method according to any of the claims 11 to 15, wherein the sheet of support material has an opening therein and the opening in the sheet of support material is covered by the spacer following step (ii).
17. A method according to claim 16, wherein the second sheet of adhesive interlayer material has an opening therein, and the opening in the second sheet of adhesive interlayer material is at least partially aligned with the opening in the second sheet of adhesive interlayer material.
18. A method according to claim 16 or claim 17, wherein the spacer comprises a portion extending from the first major surface thereof and the portion extending from the first major surface of the spacer at least partially extends into the opening in the sheet of support material following step (ii).
19. A method according to claim 18 when dependent upon claim 17, wherein the portion extending from the first major surface of the spacer at least partially extends into the opening in the second sheet of adhesive interlayer material following step (ii).
20. A method according to claim 19, wherein the portion extending from the first major surface of the spacer contacts the second major surface of the first sheet of glass following step (ii).
21. A method according to claim 15, wherein the spacer has a pattern on or in the first major surface thereof, and during step (iii) the pattern in or on the first major surface of the spacer is transferred to the sheet of support material and/or the second sheet of adhesive interlayer material.
22. A method according to any of the claims 1 to 14, wherein following step (ii) the spacer is in direct contact with the second portion of the second major surface of the first sheet of glass.
23. A method according to any of the preceding claims, wherein during step (iii) the first sheet of glass is laminated to the second sheet of glass via the interlayer structure by laminating at a temperature at least 5 °C higher than the softening temperature of the first sheet of adhesive interlayer material, preferably at least 10 °C higher than the softening temperature of the first sheet of adhesive interlayer material.
24. A method according to any of the preceding claims, wherein during step (iii) the first sheet of glass is laminated to the second sheet of glass via the interlayer structure by laminating at a temperature in the range 60 °C to 150 °C, preferably 90 °C to 140 °C.
25. A method according to any of the preceding claims, wherein during step (iii) the first sheet of glass is laminated to the second sheet of glass via the interlayer structure by laminating at a pressure in the range 5 bar to 20 bar, preferably 5 bar to 16 bar.
26. A method according to any of the preceding claims, wherein the spacer covers the entire second portion of the second major surface of the first sheet of glass .
27. A method according to any of the preceding claims, wherein an outer periphery of the spacer is alignable with at least part of an outer periphery of the second portion of the second major surface of the first sheet of glass.
28. A method according to any of the preceding claims, wherein after step (ii) and before step (iii) a first mould is provided for pressing against the second sheet of glass and/or the spacer during step (111).
29. A method according to claim 28, wherein the first mould is used to cold form the second sheet of glass during step (iii).
30. A method according to claim 28 or claim 29, wherein the first mould has a shape substantially the same as a shape of the first sheet of glass and/or wherein the first mould is a sheet of glass.
31. A method according to any of the preceding claims, wherein after step (ii) and before step (iii) a mould is provided for pressing against the first sheet of glass during step (iii).
32. A method according to any of the preceding claims, wherein the spacer comprises a plastic material, preferably wherein the spacer comprises polyethylene terephthalate, polyethylene, polyvinyl chloride, polypropylene, polystyrene, polylactic acid, polycarbonate, acrylic, acrylonitrile butadiene styrene, nylon or polyoxymethylene, or wherein the spacer comprises a rubber material preferably wherein the spacer comprises a natural rubber or a synthetic rubber, more preferably wherein the spacer comprises chlorosulfonated polyethylene (CSM), ethylene propylene diene monomer (EPDM), fluoroelastomers (FKM), polychloroprene (CR), silicone rubber (SiR) or styrene butadiene rubber (SBR).
33. A method according to any of the preceding claims, wherein prior to step (iii) the first sheet of glass has a curvature in at least one direction, and the second sheet of glass is flat, or substantially flat, or has less curvature than the first sheet of glass.
34. A method according to any of the preceding claims, wherein the first sheet of adhesive interlayer material comprises polyvinyl butyral (PVB), acoustic modified PVB, polyurethane (PU) or a copolymer of ethylene such as ethylene vinyl acetate (EVA) and/or wherein the thickness of the second sheet of glass is between 0.3mm and 1.0mm and/or wherein the second sheet of glass has been chemically strengthened and/or wherein the first sheet of glass has a thickness between 1.0mm and 10mm, preferably between 1.4mm and 6.0mm, more preferably between 1.4mm and 3.0mm and/or wherein the first sheet of adhesive interlayer material has a thickness between 0.3mm and 2.3mm, preferably between 0.3mm and 1.6mm, more preferably between 0.3mm and 0.9mm.
35. A vehicle window, in particular a vehicle side window, made according to any of the preceding claims.
36. A vehicle having an aperture for a window, in particular a side window, wherein a laminated glazing according to claim 35 is movable or fixed within the aperture.
EP20764745.4A 2019-08-23 2020-08-24 Method for making a laminated glazing Pending EP4017726A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB1912136.7A GB201912136D0 (en) 2019-08-23 2019-08-23 Method for making a laminated glazing
PCT/GB2020/052032 WO2021038214A1 (en) 2019-08-23 2020-08-24 Method for making a laminated glazing

Publications (1)

Publication Number Publication Date
EP4017726A1 true EP4017726A1 (en) 2022-06-29

Family

ID=68108956

Family Applications (1)

Application Number Title Priority Date Filing Date
EP20764745.4A Pending EP4017726A1 (en) 2019-08-23 2020-08-24 Method for making a laminated glazing

Country Status (3)

Country Link
EP (1) EP4017726A1 (en)
GB (1) GB201912136D0 (en)
WO (1) WO2021038214A1 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3112723A1 (en) * 2020-07-24 2022-01-28 Saint-Gobain Glass France GLAZING WITH A THIN GLASS HOLDER AND METHOD FOR MANUFACTURING THE SAID GLAZING

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT1027377B (en) * 1974-04-01 1978-11-20 Ppg Industries Inc LAMINATED WINDSHIELD FOR AIRCRAFT
JPS58199752A (en) 1982-05-14 1983-11-21 Asahi Glass Co Ltd Production of laminated glass
LU87241A1 (en) 1988-06-15 1990-02-28 Glaverbel METHOD FOR INCREASING THE PENETRATION RESISTANCE THROUGH A GLAZED BAY AND GLAZING WITH STRENGTHENED BREAKING RESISTANCE
DE9317460U1 (en) * 1992-12-02 1994-02-03 SEKURIT SAINT-GOBAIN Deutschland GmbH & Co. KG, 52066 Aachen Burglar-resistant car glass
FR2720831B3 (en) 1994-06-02 1996-07-12 Saint Gobain Vitrage Method for measuring the optical quality of a glazing.
GB0306259D0 (en) 2003-03-19 2003-04-23 Pilkington Plc Method to determine the optical quality of a glazing
US20150224855A1 (en) 2012-08-21 2015-08-13 Agc Glass Europe Motor vehicle glazing
WO2014148020A1 (en) 2013-03-22 2014-09-25 日本板硝子株式会社 Glass composition, glass composition for chemical strengthening, reinforced glass article, and cover glass for display
JP7021261B2 (en) * 2017-03-15 2022-02-16 サン－ゴバン グラス フランス Glass pane with electrical equipment

Also Published As

Publication number Publication date
WO2021038214A1 (en) 2021-03-04
GB201912136D0 (en) 2019-10-09

Similar Documents

Publication Publication Date Title
JP7090134B2 (en) Laminated glass
US11511525B2 (en) Laminated glazing
US11993062B2 (en) Composite glass pane
KR101870545B1 (en) Laminated glass having at least one chemically tempered pane
EP2988930B1 (en) Laminated glazing
US10035331B2 (en) Light-weight hybrid glass laminates
EP3031786B1 (en) Double glazing
KR100287307B1 (en) Intrusion Prevention Vehicle Glass Plate
EP3843993B1 (en) Laminated glazing
US20120094084A1 (en) Chemically-strengthened glass laminates
US20230264455A1 (en) Hybrid asymmetric automotive laminate
EP4017726A1 (en) Method for making a laminated glazing
US20240066839A1 (en) Laminated glazing
US20220250731A1 (en) Lightweight aircraft window with low drag
JP6988157B2 (en) Laminated glass
WO2020021269A1 (en) Process
WO2021038215A1 (en) Method for making a glazing pane
CN118043258A (en) Aircraft window with reduced weight but equal rigidity

Legal Events

Date Code Title Description
STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: UNKNOWN

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: THE INTERNATIONAL PUBLICATION HAS BEEN MADE

PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: REQUEST FOR EXAMINATION WAS MADE

17P Request for examination filed

Effective date: 20220323

AK Designated contracting states

Kind code of ref document: A1

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

DAV Request for validation of the european patent (deleted)
DAX Request for extension of the european patent (deleted)
STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: EXAMINATION IS IN PROGRESS