Non-autoclave laminated glass

Abstract

The invention provides a non-autoclave method and apparatus for producing laminated glass. The method and apparatus provide a non-autoclave laminated glass process that is continuous and thus eliminates the batch processing of known autoclave processes. In addition, the method and equipment do not require vacuum processes, involving complicated vacuum bags, vacuum rings, or the like.

1 .- 80 . (canceled) 
   
   
       81 . A method for producing non-autoclave laminated glass, the method comprising:
 a) providing a laminated glass panel comprising a desired interlayer sandwiched between at least two sheet-like substrates;   b) providing a production line comprising a plurality of ovens each followed by at least one pair of confronting press members, each confronting press member comprising a nip roller and having a diameter of at least 12 inches, each pair of confronting nip rollers is mounted to provide a separation distance that is smaller than a thickness of the laminated glass panel by between about 0.05 inch and about 0.20 inch, wherein a substrate support defines a path of substrate travel extending along the production line; and   c) conveying the laminated glass panel along the path of substrate travel and operating the ovens and the press members, wherein operation of the ovens delivers heat to the laminated glass panel and operation of the press members applies pressure to the laminated glass panel, and wherein each pair of confronting press members is operated to provide a foot path of at least about 0.5 inch on the laminated glass panel during a pressing operation.   
   
   
       82 . The method of  claim 81  wherein the desired interlayer is selected to be a film comprising ionoplast plastic. 
   
   
       83 . The method of  claim 81  wherein the substrate support comprises a plurality of spaced-apart transport rollers operatively connected to one or more motors, the method comprising operating the thus-motorized rollers such that the laminated glass panel is conveyed along the path of substrate travel at an overall rate of at least about 5 feet per minute. 
   
   
       84 . The method of  claim 83  wherein the thus-motorized rollers are operated such that the laminated glass panel is conveyed along the path of substrate travel at an overall rate of between about 5 feet per minute and about 15 feet per minute. 
   
   
       85 . The method of  claim 81  wherein the path of substrate travel has a length of at least about 40 feet, wherein the conveyance of the laminated glass panel comprises transporting it along substantially the entire length of the path of substrate travel. 
   
   
       86 . The method of  claim 81  wherein the production line comprises at least three ovens each followed by at least one pair of confronting press members, wherein the conveyance of the laminated glass panel comprises moving it through each of the ovens and between each pair of confronting press members. 
   
   
       87 . The method of  claim 81  wherein the ovens are operated such that the laminated glass panel is heated to at least about 200 degrees Fahrenheit in a single pass along the path of substrate travel. 
   
   
       88 . The method of  claim 87  wherein the ovens are operated such that the laminated glass panel is heated to a maximum temperature of between about 200 degrees Fahrenheit and about 235 degrees Fahrenheit in a single pass along the path of substrate travel. 
   
   
       89 . The method of  claim 81  wherein each of the confronting nip rollers has a diameter of at least 14 inches, wherein the conveyance of the laminated glass panel comprises pressing it between the diameters of the confronting nip rollers. 
   
   
       90 . The method of  claim 89  wherein each of the confronting nip rollers has a diameter of at least 16 inches, wherein the conveyance of the laminated glass panel comprises pressing it between the diameters of the confronting nip rollers. 
   
   
       91 . The method of  claim 81  wherein each nip roller comprises a rigid cylinder with a roll cover, wherein a radial thickness of the roll cover is at least about 0.5 inch, wherein the conveyance of the laminated glass panel comprises pressing it between the roll covers of the confronting nip rollers. 
   
   
       92 . The method of  claim 91  wherein each nip roller comprises a rigid cylinder with a roll cover, wherein a radial thickness of the roll cover is at least about 1.5 inches, wherein the conveyance of the laminated glass panel comprises pressing it between the roll covers of the confronting nip rollers. 
   
   
       93 . The method of  claim 92  wherein each nip roller comprises a rigid cylinder with a roll cover, wherein a radial thickness of the roll cover is at least about 2 inches, wherein the conveyance of the laminated glass panel comprises pressing it between the roll covers of the confronting nip rollers. 
   
   
       94 . The method of  claim 81  wherein each pair of confronting nip rollers is operated to provide a foot path of at least about 1 inch on the laminated glass panel during a pressing operation. 
   
   
       95 . The method of  claim 94  wherein each pair of confronting nip rollers is operated to provide a foot path of at least about 2 inches on the laminated glass panel during a pressing operation. 
   
   
       96 . The method of  claim 95  wherein each pair of confronting nip rollers is operated to provide a foot path of at least about 3 inches on the laminated glass panel during a pressing operation. 
   
   
       97 . The method of  claim 81  wherein each confronting nip roller has an axle about which the confronting nip roller is rotatable, wherein one axle of each confronting nip roller pair is movable vertically and the other axle of each confronting nip roller is fixed. 
   
   
       98 . The method of  claim 97  wherein the one axle of each confronting nip roller is operatively coupled with air cylinders that are operated to apply pressure via the nip rollers to the laminated glass panel during a pressing operation. 
   
   
       99 . The method of  claim 98  wherein the air cylinders are operatively coupled to an upper confronting nip roller of each pair of confronting nip rollers. 
   
   
       100 . The method of  claim 98  wherein the air cylinders are selected to be 8 inch air cylinders. 
   
   
       101 . The method of  claim 81  wherein each pair of confronting nip rollers applies pressure of between about 140 pounds per linear inch and about 160 pounds per linear inch to the laminated glass panel. 
   
   
       102 . The method of  claim 81  wherein each oven is provided with a plurality of spaced-apart heating elements, and wherein at least some of the heating elements are selected to so as to comprise quartz tube heating elements. 
   
   
       103 . A method for producing non-autoclave laminated glass, the method comprising:
 a) providing a laminated glass panel comprising an interlayer sandwiched between at least two sheet-like substrates, wherein the interlayer comprises a film comprising ionoplast plastic;   b) providing a production line comprising a plurality of ovens each followed by at least one pair of confronting press members, wherein a substrate support defines a path of substrate travel extending along the production line; and   c) conveying the laminated glass panel along the path of substrate travel and operating the ovens and the press members, wherein operation of the ovens delivers heat to the laminated glass panel and operation of the press members applies pressure to the laminated glass panel.   
   
   
       104 . The method of  claim 103  wherein the substrate support comprises a plurality of spaced-apart transport rollers operatively connected to one or more motors, the method comprising operating the thus-motorized rollers such that the laminated glass panel is conveyed along the path of substrate travel at an overall rate of at least about 5 feet per minute. 
   
   
       105 . The method of  claim 104  wherein the thus-motorized rollers are operated such that the laminated glass panel is conveyed along the path of substrate travel at an overall rate of between about 5 feet per minute and about 15 feet per minute. 
   
   
       106 . The method of  claim 103  wherein the path of substrate travel has a length of at least about 40 feet, wherein the conveyance of the laminated glass panel comprises transporting it along substantially the entire length of the path of substrate travel. 
   
   
       107 . The method of  claim 103  wherein the production line includes at least three ovens each followed by at least one pair of confronting press members, wherein the conveyance of the laminated glass panel comprises moving it through each of the ovens and between the confronting press members. 
   
   
       108 . The method of  claim 103  wherein the ovens are operated such that the laminated glass panel is heated to at least about 200 degrees Fahrenheit in a single pass along the path of substrate travel. 
   
   
       109 . The method of  claim 108  wherein the ovens are operated such that the laminated glass panel is heated to a maximum temperature of between about 200 degrees Fahrenheit and about 235 degrees Fahrenheit in a single pass along the path of substrate travel. 
   
   
       110 . The method of  claim 103  wherein the confronting members are nip rollers, and wherein the conveyance of the laminated glass panel comprises pressing it between each pair of confronting nip rollers. 
   
   
       111 . The method of  claim 110  wherein each nip roller has a diameter of at least 12 inches, wherein the conveyance of the laminated glass panel comprises pressing it between the diameters of the confronting nip rollers. 
   
   
       112 . The method of  claim 111  wherein each of the confronting nip rollers has a diameter of at least 16 inches, wherein the conveyance of the laminated glass panel comprises pressing it between the diameters of the confronting nip rollers. 
   
   
       113 . The method of  claim 110  wherein each nip roller comprises a rigid cylinder with a roll cover, wherein a radial thickness of the roll cover is at least about 0.5 inch, wherein the conveyance of the laminated glass panel comprises pressing it between the roll covers of the confronting nip rollers. 
   
   
       114 . The method of  claim 113  wherein each nip roller comprises a rigid cylinder with a roll cover, wherein a radial thickness of the roll cover is at least about 2 inches, wherein the conveyance of the laminated glass panel comprises pressing it between the roll covers of the confronting nip rollers. 
   
   
       115 . The method of  claim 110  wherein each pair of confronting nip rollers is operated to provide a foot path of at least about 0.5 inch on the laminated glass panel during a pressing operation. 
   
   
       116 . The method of  claim 115  wherein each pair of confronting nip rollers is operated to provide a foot path of at least about 1 inch on the laminated glass panel during a pressing operation. 
   
   
       117 . The method of  claim 116  wherein each pair of confronting nip rollers is operated to provide a foot path of at least about 2 inches on the laminated glass panel during a pressing operation. 
   
   
       118 . The method of  claim 117  wherein each pair of confronting nip rollers is operated to provide a foot path of at least about 3 inches on the laminated glass panel during a pressing operation. 
   
   
       119 . The method of  claim 110  wherein each pair of confronting nip rollers is mounted to provide a separation distance that is smaller than a thickness of the laminated glass panel by between about 0.05 inch and about 0.20 inch. 
   
   
       120 . The method of  claim 110  wherein each confronting nip roller has an axle about which the confronting nip roller is rotatable, wherein one axle of each confronting nip roller pair is movable vertically and the other axle of each confronting nip roller is fixed. 
   
   
       121 . The method of  claim 120  wherein the one axle of each confronting nip roller is operatively coupled with air cylinders that are operated to apply pressure via the nip rollers to the laminated glass panel during a pressing operation. 
   
   
       122 . The method of  claim 121  wherein the air cylinders are operatively coupled to an upper confronting nip roller of each pair of confronting nip rollers. 
   
   
       123 . The method of  claim 121  wherein the air cylinders are selected to be 8 inch air cylinders. 
   
   
       124 . The method of  claim 110  wherein each pair of confronting nip rollers applies pressure of between about 140 pounds per linear inch and about 160 pounds per linear inch to the laminated glass panel. 
   
   
       125 . The method of  claim 103  wherein each oven is provided with a plurality of spaced-apart heating elements, and wherein at least some of the heating elements are selected to so as to comprise quartz tube heating elements. 
   
   
       126 . A method for producing non-autoclave laminated glass, the method comprising:
 a) providing a laminated glass panel comprising a desired interlayer sandwiched between at least two sheet-like substrates;   b) providing a production line comprising a plurality of ovens each followed by at least one pair of confronting press members, wherein a substrate support defines a path of substrate travel extending along the production line; and   c) conveying the laminated glass panel along the path of substrate travel and operating the ovens and the press members, wherein operation of the ovens delivers heat to the laminated glass panel and brings it to a temperature of at least about 200 degrees Fahrenheit in a single pass along the path of substrate travel, wherein operation of the press members applies pressure of between about 140 pounds per linear inch and about 160 pounds per linear inch to the laminated glass panel.   
   
   
       127 . The method of  claim 126  wherein the desired interlayer is selected to be a film comprising ionoplast plastic. 
   
   
       128 . The method of  claim 126  wherein the substrate support comprises a plurality of spaced-apart transport rollers operatively connected to one or more motors, the method comprising operating the thus-motorized rollers such that the laminated glass panel is conveyed along the path of substrate travel at an overall rate of at least about 5 feet per minute. 
   
   
       129 . The method of  claim 128  wherein the thus-motorized rollers are operated such that the laminated glass panel is conveyed along the path of substrate travel at an overall rate of between about 5 feet per minute and about 15 feet per minute. 
   
   
       130 . The method of  claim 126  wherein the path of substrate travel has a length of at least about 40 feet, wherein the conveyance of the laminated glass panel comprises transporting it along substantially the entire length of the path of substrate travel. 
   
   
       131 . The method of  claim 126  wherein the production line includes at least three ovens each followed by at least one pair of confronting press members, wherein the conveyance of the laminated glass panel comprises moving it through each of the ovens and between the confronting press members. 
   
   
       132 . The method of  claim 126  wherein the temperature of the laminated glass panel is progressively raised during the conveyance of the panel along the path of substrate travel. 
   
   
       133 . The method of  claim 126  wherein the ovens are operated such that the laminated glass panel is heated to a maximum temperature of between about 200 degrees Fahrenheit and about 235 degrees Fahrenheit in a single pass along the path of substrate travel. 
   
   
       134 . The method of  claim 126  wherein the confronting press members are nip rollers, and wherein the conveyance of the laminated glass panel comprises pressing it between each pair of confronting nip rollers. 
   
   
       135 . The method of  claim 126  wherein each oven is provided with a plurality of spaced-apart heating elements, and wherein at least some of the heating elements are selected to so as to comprise quartz tube heating elements.