Laminated glass structure and method of manufacture

This application claims the benefit of priority under 35 U.S.C. § 365 of International Patent Application Serial No. PCT/US14/12677, filed on Jan. 23, 2014, which claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Application Ser. No. 61/757,144, filed on Jan. 26, 2013, and of U.S. Provisional Application Ser. No. 61/829,660, filed on May 31, 2013, the content of which are relied upon and incorporated herein by reference in their entireties.

The present disclosure relates generally to a laminated glass article or sheet and the methods to make it, more specifically to a laminated glass article or sheet having a finished edge imparting increased strength and break resistance at the finished edge, and the process to make it said article or sheet.

According to one aspect of the present disclosure, a laminated glass structure is provided, the structure comprising one or more inner glass layers with at least one of the inner layers in tension and two outer glass layers in compression laminated on opposing sides of one or more inner layers to form a laminated glass structure, the laminated glass structure having mutually opposing major surfaces and being bounded by one or more edges, wherein one or both of the outer layers at least partially wrap around the one or more inner layers at one or more of the edges of the laminated glass structure.

Another aspect of the present disclosure includes a process for forming a laminated glass structure, the process comprising 1) providing a laminated glass structure comprising one or more inner glass layers with at least one of said inner layers in tension and two outer glass layers in compression laminated on opposing sides of the one or more inner layers, the structure having two opposing major surfaces and one or more edge surfaces at which edge surfaces the one or more inner glass layers and the two outer glass layers are exposed, 2) removing at least some glass from at least one of the one or more edge surfaces so as to produce a concavity in at least one of the one or more edge surfaces, and 3) applying heat to the at least one of the one or more edge surfaces so as to cause one or both of the outer layers to at least partially wrap around the one or more inner layers at the at least one of the one or more edge surfaces.

Further aspects, advantages, and features of the present disclosure will be apparent from the description and figures below.

FIGS. 1A through 1C are diagrammatic cross-sections showing some aspects of a process for forming a laminate structure according to the present disclosure, and some embodiments of resulting laminate structures.

FIGS. 2A through 2C are diagrammatic cross-sections showing some steps of an alternative process to, or of a variation on the process shown in FIGS. 1A through 1C .

FIGS. 3A and 3B are computer-generated maps of cross-sectional stresses in an unfinished ( FIG. 3A ) and finished (rounded) edge ( FIG. 3B ).

FIGS. 4A and 4B are digital photographs of a cross section of an edge of one laminate structure before heat treatment ( 4 A) and after heat treatment ( 4 B).

FIGS. 5A and 5B are digital photographs of a cross section of an edge of another laminate structure before heat treatment ( 5 A) and after heat treatment ( 5 B).

A strengthened laminate is valuable because the surfaces of the glass are put in compression, desirably by an outer layer of glass having a low coefficient of thermal expansion (CTE) relative to an inner layer. This compression in the outer layer is accompanied by tension in the core of the laminate structure. Typically when such a laminated sheet is cut (such as by being scored and broken), this center tension is exposed, creating a weak spot and a potential point of breakage for the resulting glass article or sheet. Accordingly, a laminated glass structure having an edge with increased strength and damage resistance is desirable, and a method of forming such a laminated glass structure is needed.

Such advantages and such method are provided according to the present disclosure by a laminated glass structure comprising one or more inner glass layers with at least one of said layers in tension, and two outer glass layers in compression laminated on opposing sides of the one or more inner layers to form a laminated glass structure, with the laminated glass structure having mutually opposing major surfaces and being bounded by one or more edges. One or both of the outer layers at least partially wrap around the one or more inner layers at one or more of the edges of the laminated glass structure. Thus at least a portion of the edge is protected from being easily damaged and from having exposed surface area under tension.

Desirably, the outer layers wrap around the one or more inner layers to a distance of at least 1.5 times the thickness of the respective outer layer, more desirably to at least 2 times. For some applications, it is even desirable that the outer layers are wrapped around the one or more inner layers sufficiently to fully enclose the one or more inner layers at one or more of the edges of the laminated glass structure. Such structures and processes for making them are illustrated in FIGS. 1A through 1C .

FIGS. 1A through 1C are diagrammatic cross-sections showing some aspects of a process for forming a laminate structure according to the present disclosure, and some embodiments of resulting laminate structures.

In FIG. 1A , a laminated sheet 10 is provided comprising one or more inner glass layers 12 (grey) with at least one of said inner layers in tension and two outer glass layers 14 , 16 (black) in compression laminated on opposing sides of the one or more inner layers 12 . The structure has two opposing major surfaces 23 , 30 and one or more edge surfaces 40 (the edge surface at the top of FIG. 1A ) at which edge surfaces 40 the one or more inner glass layers 12 and the two outer glass layers 14 , 16 are exposed.

Next, as shown in FIG. 1B and indicated by the arrow leading to it from FIG. 1A , at least some glass is removed from at least one of the one or more edge surfaces 40 of the laminated sheet 10 of FIG. 1A , so as to produce a concavity 50 a , 50 b , or 50 c in the edge surface 40 . The concavity 50 a , 50 b , or 50 c is a concavity extending in a direction perpendicular to the opposing major surfaces 20 , 30 of the laminated sheet 10 (left to right in FIGS. 1A and 1B ). The concavity 50 a , 50 b , or 50 c may take various forms, three examples of which are shown in FIG. 1B , a broad notch 50 a (leaving only the outer layers 14 , 16 intact), a narrow notch 50 b , and a V-structure notch 50 c . The glass removal to form the concavity 50 a , 50 b , or 50 c may desirably be by performed by a laser treatment such as laser ablation, by etching, by grinding, or by any combinations of these. Other techniques may also be applied.

Next, as depicted in FIG. 1C and indicated by the arrow leading to it from FIG. 1B , heat is applied to the edge surface 40 where the concavity 50 a , 50 b , or 50 c was previously formed, so as to cause one or both of the outer layers 14 , 16 to at least partially wrap around the one or more inner layers 12 , as in finished laminated sheet 110 b at the bottom of FIG. 1C , or to completely enclose the one or more inner layers 12 , as in finished laminate sheet 110 a the top of Figure. Heating may be performed by laser and/or flame heating. Other heating methods may also potentially be applied in combination or even alone, including such methods as radiant heating and plasma heating. The natural motion of the glass under heating and the CTE/surface tension effects is sufficient to cause the outer layers 14 , 16 to bend in and partially or completely cover the inner layers 12 , as shown in FIG. 1C . The heating need not be performed in exactly the orientation shown in FIG. 1C (edge up), although this is one alternative and may be preferred in some instances.

FIGS. 2A through 2C are diagrammatic cross-sections showing some steps of an alternative process to, or of a variation on the process shown in FIGS. 1A through 1C . In this alternative process, the starting shape of the concavity 50 a , 50 b or 50 c of the step in FIG. 1B can be deeper, or otherwise modified, such as the deeper concavities 50 d and 50 e of FIG. 2A . Beginning with such deeper or otherwise modified concavities 50 d or 50 e , when the edge surface 40 is then heated, a partial seal with a void 60 at the center may be produced, as shown in FIG. 2B . This void 60 may then beneficially be used for positioning a protective and cushioning mounting interface, such as the one shown in FIG. 2C , comprising a protective sealing and mounting or fixing material 70 in cooperation with a frame 80 . Such void 60 is not necessary, but may be a beneficial alternative in cases where a groove may be desired in the edge surface 40 , for packaging, mounting, or other purposes.

FIG. 3A are computer-generated maps of cross-sectional stresses in an unfinished ( FIG. 3A ) and finished (rounded) edge ( FIG. 3B ), with the one or more inner layers 12 at the finished edge being only partially enclosed by the outer layers 14 , 16 . As seen in FIG. 3B , the corners are effectively protected by the outer (compressive) layers, and the volume of high stress glass (depicted in green shades [with a small amount of even higher stress in red]) is reduced (relative to FIG. 3A ).

Experimental

According to one present process embodiment, grinding was used to create the concavity, using the edge of a diamond saw. To apply heat to the edge, the edge was first preheated to 500-600° C. using a heated chuck and infrared radiant heaters. Next, the edge was moved through a stationary CO 2 laser beam at constant feed rate normal to the beam, with a programmed robot arm navigating the edges through the beam. The laser used produces 20-130 watts of power in a spot size having dimensions of about the width of the glass laminate by about 10 mm long in the feed direction. The feed rate was 5-20 mm/sec. (The laser power, laser spot size, and feed rate can be optimized based on the glass, the edge shape, and the extent of deformation required or desired.) After laser edge finishing, cooling is desirably performed at a controlled rate, or the glass may break. In this case, annealing at 650° C. for 1 hour was used to reduce stresses. Edges before heat treatment and edges resulting after heat treatment are shown in FIGS. 4A and 4B and 5A and 5B , with the laminate structure before heating shown in the “A” photographs, and the after heating laminate structure shown in the “B” photographs. As may be seen in FIGS. 4B and 5B , it was shown to be possible to completely enclose the inner layer(s) of the glass laminate structure using the processes of the present disclosure, without causing an increased thickness of the laminate structure. The resulting edges have a polished (a heat-polished) surface, with no machine tool marks or damage remaining.