LU87932A1 - BOMB LEAF GLAZING AND METHOD FOR MANUFACTURING SAME - Google Patents

Description

Curved laminated glass and its manufacturing process.

The present invention relates to a curved laminated glazing comprising at least two glass sheets joined together with the intervention of an interlayer adhesive material, as well as its manufacturing process.

Curved laminated glazing is commonly used as safety glazing, in particular on vehicles. They make it possible to create large picture windows which follow the forms of the bodywork of the vehicles and which provide a pleasant aesthetic effect while ensuring the required degree of security. For example, the large picture windows of modern railroad or metro cars generally have a small cylindrical curvature.

Curved glazing, whether formed from a single sheet of glass or comprising several sheets of glass, is generally obtained by heating the glass to its softening point and imparting a curvature to the sheet, by example by hot forcing on a mold. When the glass is cooled, it retains the shape that was imposed on it when hot.

In addition to the fact that this operation is complicated and expensive, it always presents a risk of deterioration beyond the optical quality of the glass sheet by the hot printing of its surface and by the possible irregularity of the curvature obtained on the whole of its surface, especially if it is large. The energy consumed to bring the glass sheets to the temperature required by the bending operation is high and increases the cost price of these curved panes. The manufacturing process for these curved panes is also very delicate since the temperature of the glass must be controlled relatively precisely. This control of the glass temperature is particularly delicate in the case of large glass surfaces.

To obtain laminated glazing consisting of curved glass sheets, the operations are further complicated since the glass sheets must have similar curvatures, adjusted very precisely so that they can be joined over their entire surface without risk of tension in the whole laminate leading to breakage of the glass or delamination of the sheets. This often leads to the rejection of curved glass sheets, which further increases the cost price of the laminated glazing produced.

The main object of the present invention is to provide curved laminated glazing of high optical quality at low cost price and its manufacturing process.

The present invention relates to a curved laminated glazing comprising at least two glass sheets joined together with the intervention of an intermediate adhesive material, characterized in that said glass sheets are originally flat sheets which are bent elastically and kept curved by said adhesive material.

The glass sheets of the curved glazing according to the invention are curved at a temperature much more moderate than the temperature necessary for the implementation of the so-called "hot" bending for which the temperature of the glass must be sufficient to permanently deform the sheets of glass. These are flat sheets maintained in the convex state by tensions internal to the laminated glazing. This preserves their original surface condition. There is no risk of damaging it by heat treatment of the glass. In addition, the convex state being obtained by an elastic bending of the glass, the curvature of the sheets is regular over the entire surface of the glazing. The elastic bending of the sheets to obtain the desired curvature also facilitates the obtaining of mutually compatible curvatures for each of the glass sheets of a laminated glazing.

It is completely surprising to maintain initially flat glass sheets forming a laminate in a bent state by the sole action of the adhesive material which secures the sheets of the laminate. Indeed, the glass sheets exert significant efforts to return to the planar state, and these efforts result in tensions inside the adhesive material. This material tends to creep to release internal tensions, which should lead in the short term to the return to the planar state of the glass sheets and therefore to the modification of the curvature and even to obtaining a glazing which does is more rounded.

We have found that, surprisingly, it was possible to maintain a cylindrical curvature making it possible to obtain a domed laminated glazing of high optical quality by the sole action of the interlayer material.

The adhesive material can be hydrated alkaline silicate. It is a material which is transparent and which can form a hard layer, not very sensitive to creep. One can for example use silicate grains obtained by drying on a rotary drum according to British patent GB 2 155 852 in the name of the applicant. A layer of these grains is placed between the glass sheets and the grains are treated so as to melt into an adhesive layer during the laminating operation. This is done at a temperature that does not exceed 150 ° C. Such glazing also has fire-fighting properties by the fact that the hydrated alkaline silicate is an intumescent material.

Preferably, the adhesive material is a thermoplastic material, as used for the manufacture of safety glazing, for example PVB. An adhesive thermoplastic material is very practical for the manufacture of laminated glazing and is very widely used. Advantageously, the modulus of elasticity of the thermoplastic material, measured at 100% elongation in tension at 20 ° C and with a tensile speed of 51 cm per minute, is greater than 6 MPa and preferably greater than 15 MPa. The tensile strength is preferably greater than 25 MPa. An adhesive material with a high modulus of elasticity facilitates the maintenance of the elastic deflection to maintain the desired curvature despite the internal forces which tend to restore the planar state of each of the glass sheets of the glazing. Such an adhesive material is less sensitive to creep than a material which has a low modulus.

Advantageously, the tensile strength of the adhesive material, measured at 49 ° C. and with a tensile speed of 51 cm per minute, is greater than 1.3 MPa. At a temperature of 49 ° C, a thermoplastic adhesive material becomes less resistant to mechanical stresses and it tends to creep. A tensile strength greater than 1.3 MPa at this temperature makes it easier to maintain the curvature of the glazing when it is exposed to temperature changes due to climatic conditions.

The glass sheets may have undergone a mechanical reinforcement treatment, such as a hardening treatment or a thermal toughening treatment. Preferably, the glass sheets have undergone a chemical toughening treatment. Such a mechanical reinforcement treatment makes it possible to resist high surface stresses, and therefore to easily withstand the tensions generated by the elastic bending of the glass sheets. This treatment also makes it possible to confer a high mechanical resistance on a very thin glass sheet and thus to obtain a very flexible glass sheet.

The laminated glazing can be glued to the frame in the appropriate housing of a bay window or the edges of the glazing can be sandwiched between parts of the frame.

In the case where the glazing could reach relatively high temperatures, the risk of creep of the adhesive is increased. In this case, it suffices to have shims between the two edges parallel to the generator of a glass with cylindrical curvature and the frame, provided that the latter has a high dimensional stability, to ensure the maintenance of the desired curvature. in all circumstances. Advantageously, shims with very fine thickness settings will be used because, for small curvatures, the difference in position of the edges parallel to the generator of a glazing with cylindrical curvature between the planar state and the curved state is minimal. An extruded aluminum profile, for example, can advantageously protect the glass at least along the edges parallel to the generatrix of the glass with cylindrical curvature.

Preferably, the glazing according to the invention comprises a rigid frame. This frame facilitates the installation of the glazing because it can be easily rigidly fixed to the frame of the bay window. It also protects the edges of the glass sheets.

In addition, the rigid frame may possibly help to maintain the curvature of the glazing if a tendency to creep occurs in the adhesive material following a very large untimely rise in the temperature of the glazing. The desired curvature is thus maintained more reliably throughout the lifetime of the glazing without risk of returning to the planar state in particular during extreme climatic conditions.

By the guarantee it provides, curved laminated glazing having a rigid frame is considered to be particularly advantageous. This is why, according to a second aspect of the invention, curved laminated glazing whose deflected state of the sheets is maintained by the sole action of the adhesive material which secures the sheets is considered to be an intermediate product. In its second aspect, the invention therefore relates to a curved laminated glazing comprising at least two glass sheets joined together with the intervention of an interlayer adhesive material, characterized in that said glass sheets are flat sheets originally which are flexed elastically and, at least partially, kept curved by said adhesive material and in that it comprises a sufficiently rigid frame to prevent any return of the glazing to the planar state.

The forces generated by the tendency to return to the planar state of each of the glass sheets can be taken up partly by the adhesive material and partly by the rigid frame.

The glazing according to this second aspect of the invention presents, in addition to its low cost price, an additional guarantee of retaining the desired curvature even when the glazing is subjected to very high temperatures which could otherwise cause the adhesive material to creep. Glazing according to this aspect of the invention is therefore advantageous in a wide field of application, for example as glazing for vehicles subjected to variable climatic conditions. It also allows a wide choice of suitable adhesive materials. The frame also allows easy attachment to the frame of the bay window. The frame can be made of aluminum or ordinary steel. Preferably, the rigid frame is formed from a metal alloy whose coefficient of thermal expansion is close to the coefficient of expansion of the glass. This characteristic, combined with the rigidity of the frame, ensures correct maintenance of the desired curvature in all circumstances. A suitable alloy can be constituted by Kovar (Trademark), which is an alloy Fe, Ni, Co.

Preferably, according to any one of the two aspects of the invention, the glass sheets have a thickness of 3 mm or less. Glass sheets of this thickness have good flexibility which makes it possible to easily obtain and maintain the desired curvature. It is preferred that the glass sheets have a thickness of 2 mm or more to obtain good impact resistance. This is particularly advantageous in the case of glazing for a railway vehicle to obtain sufficient resistance to the impact of gravel.

Advantageously, the adhesive material has a thickness of less than 1 mm and preferably less than 0.5 mm. This small thickness reduces the risk of creep of the adhesive material, especially when the latter is a thermoplastic material, and thus ensures the maintenance of the desired degree of curvature, even at the relatively high temperatures that glazing exposed to the sun can reach. Preferably, the glazing comprises a reflective anti-solar layer. This anti-solar layer can be obtained by pyrolysis, such as a layer based on oxides of Fe, Co and Cr, or by sputtering under vacuum, such as a layer based on gold or silver.

The curvature of the glazing according to the invention can have very variable values and the maximum curvature depends essentially on the internal tension admissible in the adhesive and on the mechanical resistance of the glass sheets. Preferably, the radius of curvature is greater than 5 m. Such glazing has a curvature well suited for placement in large bay windows to equip railway vehicles, such as metro cars, and they are adapted to the curved shape of the bodywork.

It is surprising that large curved panes having such a large radius of curvature and obtained by elastic bending of flat sheets can be kept in a uniformly curved state, since only a small creep of the adhesive material is required for the glazing tends to become flat again in the center for example. A radius of curvature suitable for glazing intended for a metro car is for example a radius of curvature of the order of 10 m. This curvature is small and close to the buckling limit and the relative displacement of the sheets between the curved state and the planar state is very small. The invention also extends to a method of manufacturing curved laminated glazing. The invention therefore relates to a method of manufacturing a curved laminated glazing comprising at least two glass sheets joined together with the intervention of an interlayer adhesive material, characterized in that it is assembled in the form of a sandwich of the adhesive material between two flat glass sheets, the sandwich thus formed is flexed flexibly and it is kept curved while it is subjected to the temperature and pressure conditions necessary to secure the sandwich in laminated form.

This process makes it possible to obtain in a simple manner a curved laminated glazing without thermal treatment of long bending, which is expensive and difficult to implement. It does not require any other significant treatment than the compulsory lamination operation to obtain laminated glazing, since the bending is carried out at the same time as the lamination and at temperatures clearly lower than those of the so-called "hot" bending.

It is surprising to maintain the sandwich in a domed state during a laminating operation when one knows the problems of degassing of the interfaces which one must face in order to obtain a high quality laminate. Maintaining in a domed state requires the application of a force which goes against the easy degassing of the structure. Indeed, the force applied to the sandwich to impose elastic bending on it will necessarily tend to press the sheets against each other, especially at the edges, crushing the adhesive material. As a result, the air bubbles trapped at the interface between the adhesive material and the glass sheets will find it more difficult to find a way to escape from the sandwich.

To flex the sandwich in an elastic manner, it can be placed on a mold which has the adequate curvature, force it to follow the shape of the mold and keep it applied against the face of the mold using clips for example. Preferably, the sandwich is flexed in an elastic manner by placing its central axis parallel to the generator of the desired curvature, on a cylinder whose diameter corresponds substantially to the arrow in the center which it is desired to give to the sandwich and by pressing on the edges of the sandwich parallel to this central axis. Said cylinder is for example a tube whose outside diameter corresponds to the arrow that we want to impose on the center of the bent sandwich and this tube is placed on a flat table. The sandwich is placed on the tube and a force is exerted on the edges parallel to the tube so that the edges press against the table. One can thus easily obtain any cylindrical curvature by simply replacing the tube by another of different diameter without the need to have a particular mold for each specific curvature.

Preferably, during the puff pastry, the sandwich is kept curved with a curvature greater than the desired final curvature, and for example so that it has an arrow in its center greater than 1.3 times the desired final arrow for the glazing. This makes it possible to compensate for the loss of curvature due to the balancing of the internal tensions in the adhesive material after laminating.

Hydrated alkaline silicate can be used as the adhesive material. It is a transparent material which can form a hard layer, not very sensitive to creep. Preferably, however, said adhesive material is a thermoplastic material whose elastic modulus, measured at 100% elongation in tension at 20 ° C. and with a tensile speed of 51 cm per minute, is greater than 6 MPa and advantageously greater than 15 MPa. The tensile strength is preferably greater than 25 MPa. This facilitates the glazing manufacturing process, since the loss of curvature is less when the device for holding the sandwich is removed in the curved position. This characteristic therefore avoids the need to curve the sandwich too sharply during the laminating operation.

The glazing obtained can then be glued to the frame of the bay window for which it is intended. Preferably, after joining, we encased and glued the periphery of the sandwich in a rigid frame. This rigid frame can ensure the maintenance of the correct curvature throughout the life of the glazing, and the method according to the invention facilitates the placement of the sandwich formed in the frame since the adhesive material keeps the sandwich in the proper curved state.

In a third aspect, the invention relates to a method for manufacturing a curved laminated glazing comprising at least two glass sheets joined together with the intervention of an interlayer thermoplastic adhesive material, characterized in that it flexes , in an elastic manner, a flat laminated assembly formed of said glass sheets joined together by said interlayer thermoplastic adhesive material and it is kept curved while it is subjected to temperature conditions similar to the temperature conditions which are necessary for securing such an assembly in laminated form.

The method according to the third aspect of the invention facilitates the production of curved laminated glazing without long, expensive and delicate bending and assembly procedures, since these glazing can thus be easily obtained from conventional flat laminated glazing produced in series . In this third aspect of the invention, the planar assembly in laminated form can be carried out in a specialized production line for mass production. This aspect of the invention is particularly useful for manufacturing glazings with a small cylindrical curvature.

It is surprising to heat and flex flat laminated glazing to form curved glazing, given the risks of delamination that one might have expected.

Preferably, the said assembly flexes elastically by placing its central axis parallel to the generatrix of the desired curvature on a cylinder whose diameter corresponds substantially to the arrow in the center which it is desired to give to the flexed assembly and pressing the edges parallel to this central axis. The desired curvature is thus easily obtained with a tube whose outside diameter is equal to the imposed deflection, without having an expensive mold.

Preferably, while it is subjected to said temperature conditions, the assembly is kept curved with a curvature greater than the desired final curvature, for example so that it has an arrow in its center greater than 1, 3 times the final deflection desired for the glazing. It is thus possible to accept a substantial percentage of relaxation of the thermoplastic material.

Preferably, said thermoplastic adhesive material has a modulus of elasticity, measured at 100% elongation in tension at 20 ° C and with a tensile speed of 51 cm per minute, greater than 6 MPa and advantageously greater than 15 MPa This makes it easier to adjust the curvature required for assembly and reduces its intensity.

The glazing obtained can be glued directly to bare edges on the frame of the bay window. Preferably, we encased and glued the periphery of the cooled assembly in a rigid frame. It is a simple process to obtain high quality curved glazing which is dimensionally stable.

Preferred embodiments of the invention, chosen by way of illustration, will now be described in relation to the following examples:

Example 1.

We manufacture curved laminated safety glass for the windows of metro cars. These glazings are 2.50 m wide and 1.40 m high. They must have a cylindrical curvature over the height of the glazing, with a radius of curvature of 10.81 m, that is to say an arrow of about 25 mm in the center, to adapt to the curvature of the bodywork of the car.

Adhesive material is assembled in the form of a sandwich between two flat sheets of glass. The glass sheets are sheets of 2 and 3 mm thick having undergone a chemical toughening treatment as a mechanical reinforcement treatment. The 2 mm sheet is a sheet of clear glass, while the 3 mm sheet is a sheet of gray tinted glass. The adhesive material is a polyvinyl bulyral film having a thickness of 0.38 mm. It is a "Saflex" interlayer PVB film (trademark registered by Monsanto Company) of the "AG" type. This thermoplastic adhesive has a modulus of elasticity at 100% elongation measured according to the ASTM D412 standard of 22 MPa and it has a tensile strength of 30 MPa (ASTM D412). The two sides of this film are textured so that their surface is rough to facilitate degassing of the sandwich during the laminating operation.

The sandwich formed is placed in an envelope formed by a waterproof nylon bag intended to be connected to a vacuum pump. In the center of a flat table of adequate size (2.5 mx 1.4 m). there is a tube 2.5 m long and 35 mm in outside diameter, parallel to the length of the table. The sandwich, enclosed in the bag, is placed on the tube above the table so that the great length in the center of the glazing rests on the tube. We then have a slat, on the bag, above and along each of the two large edges of the sandwich. These two edges of the sandwich are then pressed against the table by pinching between the slats and the table using a few clamps distributed along the length. In this way, the sandwich is flexed elastically and it takes a curvature whose arrow in the center is equal to the diameter of the tube, ie 35 mm. This deflection is greater than 1.3 times the desired final deflection. The table is placed in an autoclave where the pressure and temperature conditions can be controlled.

Maintaining the sandwich in this curved state, the sheets are then bonded together by the thermoplastic adhesive material using the method described in British patent GB 1,368,785 filed in the name of the Applicant.

After the sandwich has completely cooled, the clamps and the slats are removed to release the domed laminated glazing thus formed. The tensions which then develop in the adhesive material are balanced and the curvature of the glazing is reduced to almost immediately reach a deflection of 25 mm in the center. This curvature remains stable thereafter.

The glazing obtained is glued to the chassis of the metro car in the planned window.

As a variant, the edges of the glazing are encased in a rigid metallic frame, having the desired curvature, which extends around the periphery of the glazing and are glued to it. This frame is fixed with bolts to the vehicle chassis.

In another variant, two PVB films of 0.38 mm each were used to produce an adhesive 0.76 mm thick.

In a third variant, a “Saflex” interlayer PVB film (trademark registered by Monsanto Company) type “SR” was used instead of the type “AG”. This adhesive has a 100% elongation module of 7 MPa (ASTM D412) and a tensile strength of 28 MPa (ASTM D412).

In a fourth variant, the two glass sheets both had a thickness of 3 mm.

In a fifth variant, the sandwich was formed by a flat assembly already laminated in a preliminary step.

Example 2.

A curved laminated glazing of length 1.40 m and width 0.50 m is produced which has a cylindrical curvature whose generatrix is parallel to the width of the glazing and whose arrow in the center is 40 mm.

The glass sheets are sheets of clear glass 2 mm thick each, having undergone a chemical toughening treatment as a mechanical reinforcement treatment. The adhesive material used is hydrated alkaline silicate.

Silicate grains are formed according to the method described in British patent GB 2 155 852 filed in the name of the Applicant. To make the sandwich, a box is formed with the two glass sheets kept spaced 5 mm apart from one another with a flexible adhesive strip extending over three of the sides of the sandwich. This adhesive strip is perforated to allow the passage of air. The sandwich is placed vertically and the box thus formed is filled, by the side which remains open, with silicate grains of 150 to 500 μm in diameter. A layer 5 mm thick is thus formed. The fourth side is closed with the same adhesive strip. The sandwich thus formed is placed in a waterproof nylon bag and the pressure inside the bag is reduced under atmospheric pressure to facilitate holding the grains in place. As in Example 1, the sandwich is placed on a tube whose outside diameter is 40 mm placed in the center of a flat table, the sandwich is flexed elastically by pressing it on the tube and it is kept in this state curved using clamps.

The bonding is carried out in a pressurized chamber according to the method described in British patent GB 2 023 452 filed in the name of the Applicant while maintaining the curved sandwich using the clamps. The grains merge with each other, forming a transparent layer of 0.7 mm which is fairly hard and not very sensitive to creep. The glazing formed has fire-resistant characteristics by the fact that the adhesive is an intumescent material. The edges of the glazing are then protected by a silicone seal so as to remove the silicate from contact with the atmosphere. The glazing is encased in a rigid frame.

Claims (22)

1. Curved laminated glazing comprising at least two glass sheets joined together with the intervention of an intermediate adhesive material, characterized in that said glass sheets are originally flat sheets which are flexed elastically and kept curved by the said adhesive material. 2. Glazing according to claim 1, characterized in that the adhesive material is a thermoplastic material whose elastic modulus, measured at 100% elongation in tension at 20 ° C and with a tensile speed of 51 cm per minute , is greater than 6 MPa and advantageously greater than 15 MPa. 3. Glazing according to one of claims 1 or 2, characterized in that the tensile strength of the adhesive material, measured at 49 ° C and with a tensile speed of 51 cm per minute, is greater than 1.3 MPa. 4. Glazing according to one of claims 1 to 3, characterized in that the glass sheets have undergone a chemical toughening treatment. 5. Glazing according to one of claims 1 to 4, characterized in that it comprises a rigid frame. 6. Curved laminated glazing comprising at least two glass sheets joined together with the intervention of an intermediate adhesive material, characterized in that said glass sheets are originally flat sheets which are flexed elastically and, at at least partially, kept curved by said adhesive material and in that it includes a sufficiently rigid frame to prevent any return of the glazing to the planar state. 7. Glazing according to one of claims 5 or 6, characterized in that the rigid frame is formed of a metal alloy whose coefficient of thermal expansion is close to the coefficient of expansion of the glass. 8. Glazing according to one of claims 1 to 7, characterized in that the glass sheets have a thickness equal to or less than 3 mm. 9. Glazing according to one of claims 1 to 8, characterized in that the adhesive material has a thickness of less than 1 mm and preferably less than 0.5 mm. 10. Glazing according to one of claims 1 to 9, characterized in that its radius of curvature is greater than 5 m. 11. Method for manufacturing a curved laminated glazing comprising at least two sheets of glass joined together with the intervention of an intermediate adhesive material, characterized in that the adhesive material is assembled between two sheets in the form of a sandwich of flat glass, the sandwich thus formed is flexed flexibly and it is kept curved while it is subjected to the temperature and pressure conditions necessary to secure the sandwich in laminated form. 12. The method of claim 11, characterized in that flexibly, flexibly, the sandwich by placing its central axis parallel to the generator of the desired curvature, on a cylinder whose diameter corresponds substantially to the arrow in the center that one wishes to give the sandwich and pressing the edges of the sandwich parallel to this central axis. 13. Method according to one of claims 11 or 12, characterized in that, during its joining, the sandwich is kept curved with a curvature greater than the desired final curvature. 14. The method of claim 13, characterized in that, during its joining, the sandwich is kept curved so that it has an arrow in its center greater than 1.3 times the final arrow desired for the glazing. 15. Method according to one of claims 11 to 14, characterized in that said adhesive material is a thermoplastic material whose elastic modulus, measured at 100% elongation in tension at 20 ° C and with a speed of pull of 51 cm per minute, is greater than 6 MPa and preferably greater than 15 MPa. 16. Method according to one of claims 11 to 15, characterized in that after joining, it is encased and glued the periphery of the sandwich in a rigid frame. 17. Method for manufacturing a curved laminated glazing comprising at least two sheets of glass joined together with the intervention of an interlayer thermoplastic adhesive material, characterized in that a plane laminated assembly formed flexibly bends said glass sheets secured to each other by said interlayer thermoplastic adhesive material and it is kept curved while it is subjected to temperature conditions similar to the temperature conditions which are necessary to secure such an assembly in laminated form. 18. The method of claim 17, characterized in that flexes, elastically, said assembly by placing its central axis parallel to the generator of the desired curvature on a cylinder whose diameter corresponds substantially to the arrow in the center that one wishes to give to the assembly flexed and pressing on the edges parallel to this central axis. 19. Method according to one of claims 17 or 18, characterized in that, while it is subjected to said temperature conditions, the assembly is kept curved with a greater curvature than the desired final curvature. 20. The method of claim 19, characterized in that the assembly is kept curved so that it has an arrow in its center greater than 1.3 times the desired final arrow for the glazing. 21. Method according to one of claims 17 to 19. characterized in that said thermoplastic adhesive material has a modulus of elasticity, measured at 100% elongation in tension at 20 ° C and with a tensile speed of 51 cm per minute, greater than 6 MPa and preferably greater than 15 MPa. 22. Method according to one of claims 17 to 21, characterized in that one encased and glued the periphery of the cooled assembly in a rigid frame.