CN106746760A - 一种夹层玻璃的制作方法 - Google Patents
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Abstract
本发明申请属于玻璃生产加工技术领域,具体公开了一种夹层玻璃的制作方法,包括以下步骤:(1)玻璃的预处理;(2)PVB胶片的处理:在选择好的PVB胶片的厚度方向打一排孔径为0.01mm的通孔;用水清洗PVB胶片的表面,风干,将PVB胶片的含水量控制在40‑45%之间;(3)合片:将PVB胶片自然铺平,玻璃的内外片对齐合片;(4)干燥:往夹层玻璃的夹层处通入热风,干燥PVB胶片,使PVB胶片的含水率控制在0.4‑0.6%;(5)抽真空、施压;(6)高压成型。采用本方法生产夹层玻璃,操作简单,步骤小,生产的产品质量佳,且能有效避免夹层玻璃产生气泡。
Description
技术领域
本发明属于玻璃生产加工技术领域,尤其涉及一种夹层玻璃的制作方法。
背景技术
夹层玻璃是由两片或多片玻璃,之间夹了一层或多层有机聚合物中间膜,经过特殊的高温预压(或抽真空)及高温高压工艺处理后,使玻璃和中间膜永久粘合为一体的复合玻璃产品。夹层玻璃在受到外力冲击造成玻璃破裂时,玻璃的碎片仍能粘结在胶片上,因此,这种复合玻璃具有良好的安全性能。此外,这种玻璃还具有隔音、隔紫外线的特性,因而在现代建筑的***护结构及建筑内装,包括民用建筑、家用卫浴都适合应用。
现行传统干法生产夹层玻璃的工艺方法包括如下步骤:合片-第一次预压-加热-第二次预压-封边-高温高压-出高压釜-检验-入库。为了避免夹层玻璃以后容易产生气泡,即便PVB胶片含水量过低合片操作时PVB胶片与玻璃不易贴合,在合片时也必须将PVB胶片含水量控制在0.4-0.8%。两次预压和封边的关键作用就是排气和封边。若气没有完全排完已完成封边,最终产品中将留有气泡,成为不良品;若封边不完全,在高温高压步骤时,高压空气将会挤入胶膜间隙,同样形成空气间隙,导致最终产品的失败。无论封边与不封边均容易使产品产生气泡。
由此可见,传统的夹层工艺技术难以满足上述不同要求的产品生产。进一步研究开发新型夹层生产工艺并成功应用于产品生产,提高产品质量和生产效率,对提升企业的核心竞争力和企业在市场地位很有意义。
发明内容
本发明的目的在提供一种夹层玻璃的制作方法,以解决生产的夹层玻璃容易产生气泡的问题。
为了达到上述目的,本发明的基础方案为:一种夹层玻璃的制作方法,所述方法包括以下步骤:
(1)玻璃的预处理:使用高压水枪喷洗玻璃,将玻璃表面的杂质、污垢冲洗干净;擦干玻璃表面的水分,然后烘干;
(2)PVB胶片的处理:在选择好的PVB胶片的厚度方向打一排孔径为0.01mm的通孔;用水清洗PVB胶片的表面,风干,将PVB胶片的含水量控制在40-45%之间;
(3)合片:将PVB胶片自然铺平,玻璃的内外片对齐合片;
(4)干燥:往夹层玻璃的夹层处通入热风,干燥PVB胶片,使PVB胶片的含水率控制在0.4-0.6%;
(5)抽真空、施压:对步骤(4)获得的玻璃套上抽真空橡皮圈,开启气阀,对玻璃进行冷抽5-8min,抽真空的同时对玻璃施加0.6-0.8MPA压力;
(6)高压成型:将步骤(3)获得的玻璃放入高压釜,釜内温度升至60-80℃时,加压,使釜内气压达到0.8-0.9MPA;釜内继续升温至125-135℃时,加压,使釜内气压达到1.2-1.5MPA,恒温恒压保持1-1.5h;降温,降温至45℃后,排气降压至大气水平。
本基础方案的有益效果在于:清洗PVB胶片的表面,除去杂质,能使PVB胶片与玻璃粘结更牢固、且不易产生气泡。合片前,将PVB胶片的含水量控制在40-45%之间,PVB胶片含水量较高,由于水表张力和PVB胶片与玻璃的附着力,使得PVB胶片与玻璃间的液面是内向凹陷的,同时对合片后的夹层玻璃施压,PVB胶片与玻璃间的水膜层越薄,张力和附着力作用越明显,PVB胶片与玻璃间的黏结更为牢固。另外,由于PVB胶片含水量较高,PVB胶片与玻璃间形成水膜,PVB胶片与玻璃的空气被挤出,夹层玻璃没有气泡的产生,PVB胶片与玻璃间为真空状态,这样大气压力把两块玻璃紧紧的压在一起。本技术方案在步骤3)合片时,将PVB胶片的含水量控制在40-45%之间,与现有的操作步骤不同,但却取得了意想不到的效果。
PVB胶片的厚度方向设有一排通孔,往夹层玻璃的夹层处通入热风,PVB胶片上的水分通过通孔被带出夹层玻璃,使PVB胶片的含水率控制在0.5-1.0%。PVB胶片的含水率过高,夹层玻璃存放一端时间后,容易导致气泡出现,含水率控制在0.5-1.0%,能够有效避免该情况的出现。干燥后对夹层玻璃抽真空,排出通孔中的多余空气,使PVB胶片紧密贴合。
现行传统干法生产夹层玻璃的工艺方法包括如下步骤:合片-第一次预压-加热-第二次预压-封边-高温高压-出高压釜,步骤繁多,且需要多次预压,耗费能源;而采用本方法生产夹层玻璃,操作简单,步骤小,生产的产品质量佳,且能有效避免夹层玻璃产生气泡。
进一步的,所述高压水枪喷出的水为硬度低于50ppm的软化水。合片前需要对玻璃进行清洁,其目的在于将存在于玻璃表面的杂质、油污去除,使玻璃与PVB胶片黏结得更牢固。清洗需采用软化水,倘若水的硬度过大,玻璃干燥后表面会出现灰雾和白迹印,影响产品质量。
进一步的,步骤(3)中还包括用刀片切除割除夹层玻璃周边多余的胶片,使周边留有1-3mm宽度的胶片。使周边留有1-3mm左右宽度的多余胶片,这样可以避免胶片收缩造成缩膜,有助于边部的粘合。
进一步的,还包括高压成型后的封边,在气压为0.5-0.8MPA下采用聚氨酯胶对夹层玻璃进行封胶。PVB胶片由于其特定的化学结构,它对醋酸、醇类及酮类物质的耐受性差,甚至可被溶解或软化以至丧失粘结性,为了避免上述情况的出现选用聚氨酯胶进行封边。
具体实施方式
下面以实施例1为例详细描述一种夹层玻璃的制作方法,其他实施例和对比例在表1中体现,未示出的部分与实施例1相同。
实施例1
本实施例公开了一种夹层玻璃的制作方法,包括如下步骤:
(1)玻璃的预处理:使用高压水枪喷洗玻璃,将玻璃表面的杂质、污垢冲洗干净;擦干玻璃表面的水分,然后烘干;
(2)PVB胶片的处理:在选择好的PVB胶片的厚度方向打一排孔径为0.01mm的通孔;用水清洗PVB胶片的表面,风干,将PVB胶片的含水量控制在40%;
(3)合片:将PVB胶片自然铺平,玻璃的内外片对齐合片;
(4)干燥:往夹层玻璃的夹层处通入热风,干燥PVB胶片,使PVB胶片的含水率控制在0.4%;
(5)抽真空、施压:对步骤(4)获得的玻璃套上抽真空橡皮圈,开启气阀,对玻璃进行冷抽5min,抽真空的同时对玻璃施加0.6MPA压力;
(6)高压成型:将步骤(3)获得的玻璃放入高压釜,釜内温度升至60℃时,加压,使釜内气压达到0.8MPA;釜内继续升温至125℃时,加压,使釜内气压达到1.2MPA,恒温恒压保持1h;降温,降温至45℃后,排气降压至大气水平。
表1
对比例2为市场购买的夹层玻璃。
分别取实施例1至对比例2中制成的夹层玻璃100片,将上述玻璃放入潮湿、酸蚀的环境中,不时对夹层玻璃进行吹风、浇水,在不同时间段内观察玻璃的起泡率,结果如表2所示:
表2
结论:从上表的试验数据中可以看出,采用本发明方法生产的夹层玻璃质量较好,其起泡率明显比市场上销售的夹层玻璃起泡率低。
Claims (4)
1.一种夹层玻璃的制作方法,其特征在于,所述方法包括以下步骤:
(1)玻璃的预处理:使用高压水枪喷洗玻璃,将玻璃表面的杂质、污垢冲洗干净;擦干玻璃表面的水分,然后烘干;
(2)PVB胶片的处理:在选择好的PVB胶片的厚度方向打一排孔径为0.01mm的通孔;用水清洗PVB胶片的表面,风干,将PVB胶片的含水量控制在40-45%之间;
(3)合片:将PVB胶片自然铺平,玻璃的内外片对齐合片;
(4)干燥:往夹层玻璃的夹层处通入热风,干燥PVB胶片,使PVB胶片的含水率控制在0.4-0.6%;
(5)抽真空、施压:对步骤(4)获得的玻璃套上抽真空橡皮圈,开启气阀,对玻璃进行冷抽5-8min,抽真空的同时对玻璃施加0.6-0.8MPA压力;
(6)高压成型:将步骤(3)获得的玻璃放入高压釜,釜内温度升至60-80℃时,加压,使釜内气压达到0.8-0.9MPA;釜内继续升温至125-135℃时,加压,使釜内气压达到1.2-1.5MPA,恒温恒压保持1-1.5h;降温,降温至45℃后,排气降压至大气水平。
2.如权利要求1所述的一种夹层玻璃的制作方法,其特征在于,所述高压水枪喷出的水为硬度低于50ppm的软化水。
3.如权利要求1所述的一种夹层玻璃的制作方法,其特征在于,步骤(3)中还包括用刀片切除割除夹层玻璃周边多余的胶片,使周边留有1-3mm宽度的胶片。
4.如权利要求1所述的一种夹层玻璃的制作方法,其特征在于,还包括高压成型后的封边,在气压为0.5-0.8MPA下采用聚氨酯胶对夹层玻璃进行封胶。
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Cited By (7)
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CN107933054A (zh) * | 2017-11-23 | 2018-04-20 | 安徽鑫盛玻璃有限公司 | 一种夹层玻璃的加工方法 |
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CN107933054A (zh) * | 2017-11-23 | 2018-04-20 | 安徽鑫盛玻璃有限公司 | 一种夹层玻璃的加工方法 |
CN108582926A (zh) * | 2018-04-28 | 2018-09-28 | 江苏华尚汽车玻璃工业有限公司 | 一种双向防弹玻璃的制备方法 |
CN108582926B (zh) * | 2018-04-28 | 2021-02-12 | 江苏华尚汽车玻璃工业有限公司 | 一种双向防弹玻璃的制备方法 |
CN108859329A (zh) * | 2018-06-13 | 2018-11-23 | 九江市正达玻璃实业有限公司 | 一种复合式夹层玻璃的配方及其制备方法 |
CN110204224A (zh) * | 2019-05-16 | 2019-09-06 | 信义汽车玻璃(深圳)有限公司 | 通电加热夹层玻璃及其制造方法 |
CN110421945A (zh) * | 2019-08-06 | 2019-11-08 | 上海皓晶玻璃制品有限公司 | 一种无气泡夹层玻璃的加工方法 |
CN110588105A (zh) * | 2019-09-11 | 2019-12-20 | 信义玻璃(天津)有限公司 | 增厚夹层玻璃及其制作方法 |
CN110588105B (zh) * | 2019-09-11 | 2024-03-22 | 信义玻璃(天津)有限公司 | 增厚夹层玻璃及其制作方法 |
CN113386445A (zh) * | 2021-06-16 | 2021-09-14 | 海南海玻工程玻璃有限公司 | 一种夹层玻璃的加工装置及方法 |
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