Radio Frequency Lamination for Curved Windows Frequency...Radio Frequency Lamination for Curved...
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Radio Frequency Lamination for Curved Windows Shawn M. Allan*, T. Jacob Joyce, Inessa Baranova, Gibran Liezer Esquenazi, Morgana Fall, Dr. Holly Shulman Ceralink Inc. Rensselaer Technology Park Daytona Beach, Florida Troy, New York 2:10 PM January 24, 2012 36 th International Conference on Advanced Ceramics and Composites Symposium 4: Armor Ceramics: Transparent Materials
Transcript of Radio Frequency Lamination for Curved Windows Frequency...Radio Frequency Lamination for Curved...
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Radio Frequency Lamination for Curved Windows
Shawn M. Allan*, T. Jacob Joyce, Inessa Baranova,Gibran Liezer Esquenazi, Morgana Fall, Dr. Holly Shulman
Ceralink Inc. Rensselaer Technology Park Daytona Beach, FloridaTroy, New York 2:10 PM January 24, 2012
36th International Conference on Advanced Ceramics and CompositesSymposium 4: Armor Ceramics: Transparent Materials
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Outline
Flat glass & the state of the art
FastFuse™ RF lamination
Auto industry quality validation
Curved glass
Curved RF lamination
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Basic Types of Flat Glass
1 Source: http://chicagowindowexpert.com/wp-content/uploads/2009/06/shards.jpg 32 Photo source: http://en.wikipedia.org/wiki/Tempered_glass3 Photo source: By Daniel Ramirez www.creativecommons.org/licenses/by/2.0, via Wikimedia Commons
Annealed1 Tempered2 Laminated3
Lowest strengthDangerous shardsLeast processed High strength
Safer fragmentationSpecial cooling process
High strength composite2 or more glass sheets
Plastic interlayer prevents shards
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Glass Lamination State-of-the-art
Methods
Autoclave 130-140 °C, 100-300 psi
Features
Batch only 1 to 20 hour processes
Slow process development
Prevents continuous processing
Energy Intensive
Interlayers
PVB - Polyvinyl butyral – Autoglass
Clear, printed
TPU - Thermoplastic polyurethane – Armor
EVA - Ethylene vinyl acetate – Solar, Decorative
Clear, colored, opaque
Autoclave(Source: ASC Process Systems, Inc.)
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FastFuse RF LaminationLaminates faster and more efficiently
1 minute heating for autoglass
5 minutes for thick armor panels
Cuts energy over 90% vs. Autoclave
Heats interlayer directly
New process using existing equipment
De-airing with nip roller or vacuum bag
Allows fast development
50+ experiments in 1 day
Custom one-off manufacturing
Rapid quality feedback
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RF Heating & Press
Dielectric Heating: High frequency electric field creates friction
Polar “lossy” materials heatvinyl, polyurethane,
epoxy, phenolic
Non polar materials don’t heatpolyethylene, polypropylene,
silicone, ETFE, quartz
Intermediate materialsglass, acrylic,
polycarbonate, polyester
Conductive materials transmit RFcapacitive coupling
13 to 27 MHz
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RF Laminated Products: Transparent Armor, Photovoltaics, Lighting
Armor
Single pane
5 minutes in RF press18 hours in Autoclave
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Flexible PV Fabrics2 minutes in RF press
Embedded LEDs and Solderless PV cells
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FastFuse Quality Testing Autoglass
16 Auto-industry quality tests
Screening RF Lamination
ANSI/SAE Z26-1996
Pilkington Indicative Test Protocol
Flat 12” x 12” panels
Optical
Haze
Light stability
Luminous transmission
Mechanical
Abrasion resistance
Dart impact, 7 oz, 30 ft
Ball impact, 8 oz, 30 ft
Pummel adhesion
Environmental
Humidity
Cyclic humidity
Thermal cycling
QUV 2000 hours
Boil
Bake 120 °C 2 hours
Bake 90 °C 4 days
24 month exposure – Florida
24 month exposure – Arizona
6 months OK
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Environmental Test Success
Assigned “Bubble Grade” to samples
Identified significant variables
De-airing method
Pressure
Humidity of PVB storage
Achieved 120 °C, 2 hour bake PASS100
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Vac
Nip204
Pressure
Prelam
Storage
3.7778
32.222212.1111
3.6667
7.1111
94.444422.1111
5.0000
40 psi40 seconds
Nip rolledNo cooling
160 psi55 seconds
Nip rolled5 minute cool
40 psi55 secondsNip rolledNo cooling
160 psi55 secondsVacuum5 minute cool
23 Factorial Designed Experiment
40
160
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FastFuse Quality Testing Autoglass
16 Auto-industry quality tests
Screening RF Lamination
ANSI/SAE Z26-1996
Pilkington Indicative Test Protocol
Optical
Haze
Light stability
Luminous transmission
Mechanical
Abrasion resistance
Dart impact, 7 oz, 30 ft
Ball impact, 8 oz, 30 ft
Pummel adhesion
Environmental
Humidity
Cyclic humidity
Thermal cycling
QUV 2000 hours
Boil
Bake 120 °C 2 hours
Bake 90 °C 4 days
24 month exposure – Florida
24 month exposure – Arizona
6 months OK
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Mechanical Impact Testing
Dart Impact from 30 ft
5 panels
PASS – no penetrations
Ball Impact from 30 ft
12 panels
PASS – no penetrations
Dart Impact
Ball Impact
Keller, U.; Mortelmans, H., Adhesion in Laminated Safety Glass - What Makes it Work? Glass Processing Days 1999, (June 13-16), 353-356.
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Pummel Adhesion Success
Pummel adhesion initial FAIL
Subjective 0-10 scale
Low adhesion
Identified improvement plan
High adhesion PVB
Low humidity PVB storage – 4% RH
Higher pressure – 160 psi
Pummel 0-1FAIL
Pummel 3PASS
Pummel 7PASS
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FastFuse Quality Testing Autoglass
16 Auto-industry quality tests
Screening RF Lamination
ANSI/SAE Z26-1996
Pilkington Indicative Test Protocol
Optical
Haze
Light stability
Luminous transmission
Mechanical
Abrasion resistance
Dart impact, 7 oz, 30 ft
Ball impact, 8 oz, 30 ft
Pummel adhesion
Environmental
Humidity
Cyclic humidity
Thermal cycling
QUV 2000 hours
Boil
Bake 120 °C 2 hours
Bake 90 °C 4 days
24 month exposure – Florida
24 month exposure – Arizona
6 months OK
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Curved Glass – Slumping
Flat annealed glass is heated (500-700 °C)
Bending by gravity
Two or more pieces of glass
Low tolerance method
No inner mold
Only slumped mates matchSource: Bullseye Glass Co.
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Curved Glass – Press Bent
Precise molds
Inner & outer panes pressed separately
Any inner & outer panes will match
Much more expensive tooling (over $100,000)
Tighter glass specifications
Opportunity for successful RF press lamination
Press bent panes used in this study
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Curved Window Lamination
Developing process with rear car side window
Nissan Maxima window (Pilkington Automotive)
Tempered glass
77 in2
In autoclave hydrostatic pressure no tooling required
RF Press needs tooling to conform to curved surfaces
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2011 Nissan imagery courtesy of Nissan
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Curved RF Platens
Platens must be electrodes 7 kV
130-150 °C max use
Numerous mold materials
Rigid
Conforming
Machined
Castable
Functional
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Development of Curved Platens
High strength polymer foam mold
Casting the molds
RF ready Assembly
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Curved Lamination Testing
90 second RF press from room temperature
Even pressure distribution over curved surface
Window lay-up Plaster platens in press
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Curved Lamination Success
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Curved RF Lamination Summary
1st demonstration of CURVED RF Lamination
1st demonstration of TEMPERED RF Lamination
Auto industry quality achieved
Significant development for
Autoglass
Aerospace
Armor
Maintaining over 90% lamination energy reduction
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AcknowledgementsSponsorsU.S. Department of Energy, Industrial Technologies Program
Industrial Grand Challenge Award No. DE-EE0003453
New York State Energy Research & Development AuthorityInnovative Products and Process Improvement
CollaboratorsPilkington North America
Joe Poley, Scott Chambers
Thermex-ThermatronJoe Fox, Mark Isgrigg
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Thank you! Questions?Ceralink Inc. develops advanced materials,
green processes, and new products for industry.
Shawn AllanSr. Materials Engineer
(518) [email protected]
www.FastFuse.net
Patent PendingFastFuse™ RF Lamination Technology
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mailto:[email protected]://www.fastfuse.net/
Radio Frequency Lamination for Curved WindowsOutlineBasic Types of Flat GlassGlass Lamination State-of-the-artFastFuse RF LaminationRF Heating & Press�RF Laminated Products: �Transparent Armor, Photovoltaics, LightingFastFuse Quality Testing�AutoglassEnvironmental Test SuccessFastFuse Quality Testing�AutoglassMechanical Impact TestingPummel Adhesion SuccessFastFuse Quality Testing�AutoglassCurved Glass – SlumpingCurved Glass – Press BentCurved Window LaminationCurved RF PlatensDevelopment of Curved PlatensCurved Lamination TestingCurved Lamination SuccessCurved RF Lamination SummaryAcknowledgementsThank you! Questions?
