Common Defects and Solutions in Autoclave - Free Glass Laminated Machines

Autoclave free glass laminating machines have become extremely popular in the last few years among glass manufacturers because they consume low power, have lower production cost, and are small in size as compared to traditional autoclave-based systems. However, like all other machines that are employed during manufacturing, there are also certain defects that they impose which affect the quality of laminated glass products. Familiarity with such common issues and resolutions is crucial to achieving consistent quality output and reducing machine downtime.

Poor Glass Interlayer Bonding

Defect Description

One of the most prevalent issues in non-autoclave glass interlayers is poor glass interlayer bonding. Delamination may occur in the long run if the interlayer material does not stick properly to the glass. Cracks or lines of separation are visible on the borders of the laminated glass panel or even along the entire panel, and this can significantly reduce its structural integrity as well as appearance.

Causes

There are many reasons why this problem may occur. Inadequate cleaning of the glass surface well before lamination is one of them. Grease or dust or other contamination of the glass surface is an insulant that hinders the interlayer from bonding correctly. Wrong temperature and pressure settings in the lamination process are also significant factors. If the temperature is too low, interlayer material will fail to soften enough to stick to the glass, and excessive pressure can extrude too much interlayer material, leaving them thin spots and weak bonds. Additionally, the integrity of the interlayer material itself, such as degradation or water absorption resulting from storage in the wrong conditions, can also have an impact on the bonding effect.

Solution

For resolve poor bonding issues, adequate glass surface preparation is essential. Use high-quality cleaning agents and equipment to remove all contaminants from the glass. An automatic washing machine for glass with brushes and flushing appliances ensures a clean and even surface. Temperature and pressure control are achieved by having the machine settings appropriately calibrated to the particular requirements of the interlayer material and glass thickness. Routine maintenance checkup of pressure and heating components should be conducted to ensure that they are not malfunctioning. Interlayer materials should be kept under a controlled environment with good temperature and humidity. Materials should be checked for damage or degradation before use and should be stored and handled in accordance with the supplier's guidelines.

Bubbles in Laminated Glass

Defect Description

Bubbles in laminated glass represent a typical defect that occurs in size from extremely small pinholes to significantly large and visible round bubbles. Besides affecting the visual transparency of the glass, they also weaken its structural integrity because bubbles create areas of reduced strength within the interlayer.

Causes

There are several causes for which bubbles might be formed. When the air between the glass panes and the interlayer is not evacuated properly while laminating, it can become trapped. This could happen if the machine's vacuum sealing mechanism fails, or if the evacuation time is too short. Moisture on the interlayer or the glass surface is another cause. When they are heated, water becomes steam, and steam creates bubbles. Also, when the interlayer material is not properly handled, such as creasing or folding it when being installed, air pockets can be created.

Solution

To eliminate bubbles, make sure the vacuum sealing system of the non autoclave laminate machine is in proper working condition. Check seals for leaks regularly and replace or repair as needed. Increase the pump-down time during lamination to allow adequate time for air release. Make sure glass and laminating materials are completely dry before laminating. Utilize a dehumidifier in the work area if needed to control humidity. When processing the lamination, extra precautions should be taken so that there are no creases or wrinkles. A pre-lamination degassing is also a feature of some advanced machines to further minimize the chances of bubble formation.

Uneven Thickness and Warping of Laminated Glass

Defect Description

Glass laminate at times tends to be of an irregular thickness across the panel, with thicker or thinner sections in some locations. This irregular thickness leads to warping, where the glass panel is warped and no longer flat. Warped glass not only becomes difficult to install, but also affects overall performance of the glass for such applications as windows or curtain walls.

Causes

Uneven pressure distribution during lamination is mainly accountable for uneven thickness. If the parts of an autoclave free glass laminating machine that supply pressure are out of calibration or worn, it can impart excess pressure at certain points and low pressure at other points. Irregular heating also leads to this problem. If different parts of the glass are heated to different temperatures, lamination material will flow and be bonded unevenly, resulting in unequal thickness. Furthermore, misalignment of glass layers before laminating can result in one side being compressed relative to the other, resulting in warping.

Solution

Regularly calibrate and maintain the autoclave free glass laminating machine’s pressure and heating components. Use pressure sensors and temperature monitoring equipment to ensure uniform pressure and temperature distribution across the glass panels. Perform a quality check on the alignment of the glass layers before starting the lamination process. Some machines provide automatic aligning devices for precise positioning of the glass sheets. In the event of warping, it can sometimes be rectified by re-laminating under extremely controlled temperature and pressure conditions, but this is not always possible depending upon the degree of the defect.

Conclusion

In general, even though autoclave-free glass laminating machines are comprised of many advantages, they also have to face a series of challenges. As the mutual defects between them are grasped and the appropriate solutions adopted, glass manufacturers can guarantee the high-quality production of laminated glass products, better operate, and maintain competitive advantage in the market. MERSGlass is an export-experienced autoclave-free glass laminating machine manufacturer with many years. We offer machine use guides and maintenance services. If you are interested, feel free to contact us!