CA1332701C - Articles including thermosetting-powder surface-coatings - Google Patents
Articles including thermosetting-powder surface-coatingsInfo
- Publication number
- CA1332701C CA1332701C CA000571528A CA571528A CA1332701C CA 1332701 C CA1332701 C CA 1332701C CA 000571528 A CA000571528 A CA 000571528A CA 571528 A CA571528 A CA 571528A CA 1332701 C CA1332701 C CA 1332701C
- Authority
- CA
- Canada
- Prior art keywords
- glass
- powder
- coating
- sheet
- panel
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10165—Functional features of the laminated safety glass or glazing
- B32B17/10247—Laminated safety glass or glazing containing decorations or patterns for aesthetic reasons
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
- B32B17/10018—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising only one glass sheet
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
- B32B17/10036—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising two outer glass sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10165—Functional features of the laminated safety glass or glazing
- B32B17/10174—Coatings of a metallic or dielectric material on a constituent layer of glass or polymer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10807—Making laminated safety glass or glazing; Apparatus therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10807—Making laminated safety glass or glazing; Apparatus therefor
- B32B17/10899—Making laminated safety glass or glazing; Apparatus therefor by introducing interlayers of synthetic resin
- B32B17/10935—Making laminated safety glass or glazing; Apparatus therefor by introducing interlayers of synthetic resin as a preformed layer, e.g. formed by extrusion
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10807—Making laminated safety glass or glazing; Apparatus therefor
- B32B17/10899—Making laminated safety glass or glazing; Apparatus therefor by introducing interlayers of synthetic resin
- B32B17/10944—Making laminated safety glass or glazing; Apparatus therefor by introducing interlayers of synthetic resin in powder form
Abstract
Abstract Articles including Thermosetting-Powder Surface-Coatings Manufacture of an article incorporating a thermosetting -powder surface-coating includes bonding a component of the article to the coating by contacting the melted powder with the component before curing takes place, and maintaining it in contact through curing. In a glass architectural panel, an aluminum foil is bonded in this way to a polyester/triglycidyl-isocyanurate powder coating on the silane-primed back of the facing glass; the metal foil is backed by a plastics or rubber open-cell material to enhance resistance of the glass to impact, and also, together with the foil, resistance to thermal shock. The coating includes pigmentation to give the effect of colored glass, or is clear to allow the contact-surface of the metal to show through; and further decorative effect is obtained by pigmentation variation in the coating and/or partial metallization of the glass back-surface.
The technique is also applied to bonding fittings to the powder-coated face of a door; of decals of cured powder-coating material to, or within, powder-coatings;
of glass over apertures in metal walls; and of glass to glass in building up a laminate.
The technique is also applied to bonding fittings to the powder-coated face of a door; of decals of cured powder-coating material to, or within, powder-coatings;
of glass over apertures in metal walls; and of glass to glass in building up a laminate.
Description
`~
1 ~32.7~
Articles that include Glass ~hee~n~
This invention relates to articles that include glass sheeting.
The invention is particularly concerned with articles of the kind that include a bond between a glass sheet and another component, and especially with methods of manufacturing such articles.
'~'`
According to one aspect of the present invention, there is provided a method o~ manufacturing an article that includes a bond between a glass sheet and another component of the manufactured article, wherein the bond is formed by thermosetting organic powder-coating material, the powder being heated to melt it in contact with a surface of one of the components, and wherein, prior to curing and while the powder is in a melted ~0 condition, contact is established between the melted powder and a sur~ace of the other component, and such contact is maintained during curing so as to ~orm said bond.
: .
~-~ 25 l'hermosetting organic powders are known in the context o~ the manufacture oP, ~or example, panels ~or doors, partitions and other purposes in whiah at lea~t the ~ront sur~aae o~ a sheet o~ metal that i~ to provide the eacing ~heet oP the pan~l, is aoated evenly with an 30 epoxy or other ~hermosetting organic powder.l Stoving ~
then takes place to heat the powder to a kemperature at `
.
which it melts and cures so as to form, on cooling, a hard protective face-coating to the metal sheet. The~ ;~
coating af~ords protection to the metal, and pigmentation in the powder can be used to give color ~or decorative ef~ect.
`: :
13~2701 It has been found that the known powder-coating technique can be extended to achieve a bond with glass sheeting that is of particularly advantageous effect.
Using the method according to the present invention, a very firm bond between a glass sheet and another component o~ the manufactured article can be achieved via the coating.
Thus, not only can the advantages o~ the powder coating be realised ~or protective and/or decorative effect, but they can be combined with the advantage of the adhesive efPect. More especially, it has been found that the invention is of significant advantage in the provision o~ glass cladding for both exterior and interior architectural purposes.
In the latter respect, the coating is advantageously applied to the back sur~ace of the glass, so that `~
whether the glass iisi clear or otherwise, pigmentation o~ the coating is revealed throuyh the glass to give ~I the ePfect o~ color in the glass. Where no pigmentation is used, and/or depending on the transparency of the coating, the component bonded to .
~he back of the coatiny may also contribute to the ~5 vlsual e~Pect in the ylass.
~lowever, even where coloration or other decorative e~ect is not sought, particular advantage ls obtainable in another re~pect 1~ the backing aomponent bonde`d with thelcoating is o~ thèrmally conduativèl ma~erial, for example aluminium ~oil, and covers the~ `
coating surface to a~substantial~extent, siince such component will then have the effect of tending to e~uaIize temperature across the glass sheet. This facilitates the use of annealed glass in contexts where it would not o~herwise be acceptable or possible to use ~ , ;`;
."' ' .
1 332701 ~: `
it, in particular for architectural colored-glass cladding.
The glass conventionally used for architectural 5 cladding, is toughened, and this precludes cutting to ;
size, and ease of fitting, on site; toughened glass is used in order to withstand temperature gradients, and also to resist impact without splintering dangerously.
Use o~ annealed glass instead o~ toughened, would be prePerred, since such glass is cheaper and can be cut on site, but annealed glass does not in general withstand temperature gradients and provide adequate resistance to impact, within the normal sa~ety criteria.
The present invention makes it possible for this pre~erence to be exerclsed, in particular because the use oP a thermally-conductive sheet as the component bonded to the back of the powder coating applied to the ; 20 glass, can be e~Pective to reduce temperature gradients ~ ;
across the glass to an extent adequate to allow annealed qlass to be used in a wide range o~
~ architectural environments. ;
;~ ~5 The Pact that color or other decorative e~Pect can readil~ be provided, as rePe~red to abov~, in ~uch gla~, ha~ an additional advantage in thi~ context, ~lnce r~uire~ent Por color or other decorative e~ect inl claddingllglass would normallylmake ulse o~ltoughlened glass essential.
Thus, according to a ~eature of the present invention, in a method~o~ manufacturing a panel ~or architectural or other purpose, in which a thermosetting organic powder-coating material applied to a surfaae o~ a Pacing ~heet oP the panel is heated to melt and cure the powder and thereby form a coating bonded to the .~ ~'.` .
' ! ,;. '~
surface, the facing sheet is a glass sheet, the coating is applied to the back of the glass sheet, and, prior to curing and while the powder is in the melted condition, contact is established between the melted powder and a surface of a thermally-conductive sheet, such contact being maintained during curing so that the sheet is thereby bonded, as a thermally-conductive backing, with the cured powder coating.
This feature of the present invention is applicable to toughened glass as well as to annealed glass, but, as indicated above, the application to annealed glass has special advantage.
.:
Resistanae to impact and thermal shock o~ the glass can be enhanced to a very substantial degree - especially where annealed glass is used - by bondinq an open-cell material in the form, for example, of a flexible and compressible ~oamed plastics or rubber layer, to the backing sheet. A rigid board of, for example, wood or foamed plastics, may be bonded behind this latter layer to give added strength to the panel.
In the method of the present invention as presented generally and ~pecifically above, an adhesion pxomotar m~y b~ used to pr~-coat the surface that i~ to receive ; applioation ~or example, electrostatically) o~ the powder-coating material. ~he pro~oter ~ay be a 9ilane, and in ~hi~ re~peot may be applied as a solutlon o~ the silane in~a blend o~ water with isopropanol or another alcohol. The silane may be an organosilane ester.
The invention also relates to articles produced according to the methods of the present invention as these are referred to in the general and specific terms set out above.
B
1 3327n ~
5 73062~
More especlally, and according to another aspect of the ~;;
present invention, there is provided a panel ~or architectural or other purpose, in which a facing sheet o~ the panel carries a coating of cured thermosetting organic powder material, wherein the facing sheet is a glass sheet, the coating backs the glass sheet, and the coatlng ls backed by a sheet that is bonded to the ~
ylass sheet by the cured powder material o~ the coating. ~;
The coating may be pigmented to show color in the glass faaing, and the backlng sheet may be thermally-conductive;
aluminium ~oil may be used with advantage in this respect. ;
Furthermore, open-cell material, ~or example in the form of a ;`
layer o~ flexible and compressible foamed plastics or rubber, may be bonded to the backing sheet.
Examples of articles and methods of their manufacture in accordance with the present invention, will now be described, wlth reference to the accompanying drawings, in whiah, Figure 1 is a pexspeative view of part o~ an architeatural panel ln accordance with the present lnvention;
Figure 2 is a sahema~ia representation o~ par~ o~ a produ~tion line ~or manu~acturing the architeatural panel o~ `
Figure 1 using a method aacordin~ ~o the present invention~
~ Flg,ure 3 i8 illlustratjive~o~ modi~ication~o~ the panel,o~;
Figure l;
Figure 4 illustrates another method of manufacture according ;~
~; to the present invention; and ~ , .. ..
::
Figures 5 and 6 are sectional side-views of further articles that in both their structure and method of manufacture, are in accordance with the present invention.
~ :
The architectural panel to be described with reference to Figure 1, is of a form suitable for use in providing glass cladding to exterior or interior walls of ::
buildings. For this application, the panel is rectangular with glass-face dimensions of some 3 x 1.2 metres, and an overall thickness of some twenty-eight "
~ .
7 137)~701 millimetres; clearly panels of larger or smaller dimensions can be provided.
Referring to Figure 1, the panel is faced by a sheet 1 of clear, annealed glass having a thickness of 4 millimatres. The glass sheet 1 is backed by a cured polyester powder-coating 2 bonded to the sheet 1 via an interlayer 3 of silane adhesion-promoter. The interlayer 3 is very thin (perhaps only one molacule thick), and the coating 2, which has a thickness in the range rom 60 to 120 microns, con-tains a pigment to show color in the glaqs facing and give the visual efeat o colored glass to the cladding panel.
The coating 2 has a backing o~ aluminium foil 4 that is bonded to the sheet 1 via the coating 2 ln the process of stoving the polyeQter powder-coating 2 on the glass sheet 1. The foil 4 has a nominal thickness of 0.1 millimetre, and being of good thermal conductivity, serves to equalize tamperature variations across the panel. The function of the foil 4 in this latter regard is important in the context of the use o~
annealed glass, which 18 less reslstant to temperature gradlents than toughened glass, especlally in exterior applicatlon~ where part of the panel may be in sunlight and part in shadow. ~owever, the ~oil 4 al~o has a protective ~unotion in relation to the general porosity o~ tha coating 2, the foil ~ in this regard proteating the coating 2 again~t degradation ~rom moisture and weathering generally;~ ~he nature o~ the intlmate bond obtained aoaording to the invention, between the coating 2 and the foll 4, without the need for introduation of an adhesive interlayer between them, is espealally advantageous.
Even to the llmited extent that the panel of Figure 1 has so far been described, it ls capable o~ being used ~or oladdlng purposes, whether in the ~orm o large sheets as described, or smaller tilas. In particular, the use of annealed glass enables the panel to be readily cut to size on site, but the usefulness of the panel, in particular its capabillty of resisting impact and thermal shock, is greatly enhanced by the addition, as illustratad in Figure 1, of an element 5 of flexible and compressible open-celled foamed plastics or rubber material, bonded to the back of the alumlnium foil ~.
The element 5 is in the Porm of a layer of some 3 millimetres in thickness, and has both faces aovered by layers 6 and 7 of finely-woven or knitted nylon mesh that has been flame-welded to the layer 5; the mesh serves to stabilize the layer during its bonding into the panel. A rigld board 8 o~ fo~med polyurethane and/or polyisocyanurate or phenolic resin, ~aaed with sheets 9 and 10 of aluminlzed paper or glass ~ibre, is bonded to the element 5 via the facing layer 7, to add rigidity and further damage-protection to the panel without detraating from the ease of outting and fitting on site.
As lndicated above, the foil 4 has a ~ignificant effect in e~uali~ing temperature variation3 acro~s the panel, as well as providing protectlon ~or the aoating 2.
Incorporatlon o~ the open-cell element 5 lnto the panel to back the ~oll 4, not only signi~i¢antly enhance~ the ~esi~tance of the glass to lmpaot, but al~o adds ~urther ~o its ability to withstand temperature di~erential between ad~acent arqas of the glass. The open-cell str~ature,tend~ to promote the disp~rsion of haat aoross the glass, and thereby tends to reduce temperature gradients, by retarding movement of hot gas away ~rom the foil 4 and enhanoement of lts movement across the baok of the panel.
~ests with annealed gla~s have lndicated that the aapaaity o~ the glass to withstand temperature di~erential was increased by some 80 to 90 degrees -1 3:~701 Cel~lus when provided with the coating 2 and its foil 4 backed by the element 5. Furthermore, such tests have shown that as well as greatly increasing lmpact resistance of the glass, the construction reduces significantly the extent of splintaring when the glass does eventually break.
~he method o~ manufacturlng the panel wlll now be described with raference to Figure 2, which lllustrates part of a production line for manu~acturing panels o~
the form shown in Figure 1, in a continuous process.
The manu~acturing process will be described, and the production line is illustrated in Figure 2, only up to the stage at which the glass sheet 1 has been provided with the cured coating 2 and its aluminium foil-backing. The addition of the layer-element 5 and board 8, is carried out ln essentially the same manner as the provislon o~ like layer~ and boards for mirrors, desoribed in U~ Patent No 2,048,166, and will not be descrlbed here.
Referring to Figure 2, the sheet 1 of gla88 iS loaded face down on a conveyor at the first s-tation 11 o~ the productlon line, and is transerred by the conveyor tQ
a aleaning statlon ~2 where all loose debris i9 removed ~rom both ~aces oP the sheet 1 by means o~ a vacuum cleaner. The sheet 1 then paq~e~ on the conveyor throuyh a washin~ station 13 where i't8 upper, back, sur~ace i~ ~prayed with a solution o~ isopropanol and distilled water,i and scruhbed by rotatlng brùshes to remove all dirt, before bein~ wiped or air-blown dry of excess solution.
From the washing station 13, the glass sheet 1 passes lnto a spray statlon 14 where the upper sur~ace o~ the sheet 1 is sprayed with a ~ine mist o~ a solution of silane in a blend of isopropanol and dlstilled water.
As the sheet 1 leava~ the station 14, warm air is lo 13~70~
directed at the glass to dry the glass surface and leave it coated with the thln interlayar 3 of silane, before the sheet 1 passes to the next, powder-deposit station 15.
The station 15 includes provlslon for electrostatic or tribostatic deposition of polyester powder-coating material on the silane-coated upper surface of the 3heet l. The powder, which i8 the milled product of extruding a melted mixture o~ a polyester resin, cross-llnklng agents and pigments, is deposited on the upper sur~ace o~ the sheet 1 evenly, and to a depth within the range 60 to 120 microns, by regulating the uni~ormity and speed of progress of the sheet 1 through the station 15. As the sheet 1 leave~ the station 15, the lower, front face of the glass is brush- and vacuum-cleaned to ensure that none of the powder remainq on this Pace.
~he sheet 1 now enters a melt station 16 where infra-red heater~ maintain a temperature in the range 150 to 170 degree~ Celsiu~, so as to melt the powder, The heat is applied uniformly across the whole body o powder for a period o~ some two mlnute~ before the sheet 1 moves to a foil-application station 17 ~or reaeivlng the ~heet of aluminium foil 4. In thls regard, ~oil i8 di~pensed from a supply roll ~not shown) onto the melted powder vla heated siliaone-coatQd rollers 1~ and 19; the heatirly of the rollers 18 and 19 i~ su~fialent to,avoid any aonden~ation on ~the ~oil. The sheet 1 is ~topped momentarily as the leading edge of the foil is brought down onto the leadlng edge of the melt under a roller 20, and is then carried forward with the foil pressed downwardly by the roller 20 into sur~ace contact with the laysr of melted powder. The downward pres~ure is maintained a~ the foil is fed at an angle onto the moving melt-surface under the roller 20, so as to ensure that air which ;
~3~270~
would otherwise be entrapped under the foil, iis squeezed out. When the whole of the melt is covered, the sheet 1 stops momentarily again to allow a flying knife 21 to cut the ~oil at the trailing edge. This divides o~ from the supply web the elament of foil, namely the foil 4, that now lies in full surface contact wlth the body of melted powder, and enables the sheet 1 to move out of the station 17 into a curing ~tation 22.
The alr temperature within the curing station 22 lies wlthin the range o~ 210 to 230 degrees Celsius, so as to raise the temperature o~ the assembly o~ sheet 1, melted powder and foil 4, to some 200 degrees Cel~lus.
The assembly i.s maintained at this level o~ temperature for ten mlnutes, in order to cure the powder and affect the bonding to the sheet 1 and foil 4. A~ter thls, the sheet 1 wlth its cured coating 2 and adharing foil 4, pass lnto a cooling station 23 and thence to an ~0 unloading station 24 for subsequent attachment o~ the backing element 5 and board 8, as required.
It has been found that the ~ured powder-coating provides not only good ooloration (aacording to th~
partlcular pigmentatlon used in the powder) ~or the vlsual ef~eat ln the glass, but also a strong bondlng between the glass and the foil 4. Moraover, the manu~acturing me~hod described, has been .~ound to result in a product whioh is ~ree rom air bubbleis and rlpples betwe~nlthe glass and coating, and between the coating and foil ~, and for which the color-view in the glass ls uniform and wlthout blemish, aoross the full area o~ the ~ront ~ace of the panel. Reduction in the po~slbllity o alr or other gas bubbles afectlng the coating can be achieved i~ the meltlng and curlng stages o~ the method are carried out in a reduced-pressure or partial-vacuum atmosphere.
- . . , . , . " . . . . ... .. . .... .... . ...... . . ......... ..
The particular powder-coatlng material preferred for use in the context of the panel described above, is a polyester resin containing a catalyst agsnt with a triglycidyl isocyanurate curing agent; the powders sold as PPL858G and PPH857G under the trade mark DURAPLAST
by Holden Surface Coatings Ltd. of Birmingham, England, are appropriate in this respect. Such powders provida structures that not only have good bondlng, but have also been found to be markedly reslstant to the e~fects o~ humidlty and o~ salt, sulphur dioxide and other pollutants in the atmosphere, and to sunlight.
Although the polyester/triglycidyl-isocyanurate powders have been found advantageous in the above context, other polyester powders, and epoxy-, acrylic- and polyurethane-based powders, may be applicable in appropriate circumstances. Powders combining a polyester resln with an epoxy curing agent have, in particular, been found to provide acceptable results.
~0 The use o~ an adhesion promoter on the glass is desirable to ~acilitate a good bond wlth the powder coating; as lndicated above, a sllane has been use~ ~or thi~ purpose. More especlally, it ha~ been found that an or~ano~ilane ester ~aallitates good bondin~ when applied in a solution contalning 3 per cent by volume o~ the silane in a blend o~ isopropanol and distllled water ~or whlah the ratio o~ isopropanol to water is 4:1 by Yolume~ Gamma-mexaaptopropyltrimethoxy~ilane ha~ been ~oun~ ~spea~ally e~eotive when used ln this way; the produat sold under the Trade Mark UNION
CARUIDE as Organofunctional Sllane A-189 by Union Carblde Corporation ls appropriate in thi~ respect.
The foil used to back the powder aoatin~ i preferably an alumin~um-alloy foil o~ hard temper that has been pre-treated by the rlnse method with a mlxed alumlnium phosphate and chromlum III phosphate prlmer. The use of a hard temper facilitates easy and clean cutting of the panel.
Various decorative effects beyond uniform coloratioQ, can be readily obtained with a glass-~aced panel constructed in the general manner described with reference to Figure 1. In partlcular, a combined mirror and color effect can be achleved by sputtering or otherwise depositlng a thin layer o~ metal on part or parts o~ the back sur~ace of the glass prior to coating lt with powder (~or exampl0, prlor to entry into station 14 of the production line illustrated in ~lgure 2); the metallized part or par-ts give a mirror e~fect with the pigmentation of the cured powder-coating showing in the glass elsewhere. Alternativelyor in addltion, di~erent pigmentations may be used in difPsrent-areas, simply by ~epositing the di~farently-pigmented powder~ on the back surface of the glass where required (~or example, within station 15 o tha production line illustrated in Figure 2); there is minimal di~usion o~ pigmentation across the interface between powders during the melt and curing phases.
Either (or both) o~ these technlques may be applied, ~or example, to the provision o~ dlstinative let-tering or other s~mbology in the glass, ais will now be d~aribed with re~erence to Figure 3 which lllu~trate~
the letter ~ aY thls i8 both delineated on part of the baa~ sur~ace o~ the glass and i8 vislblo in the gla~s ~rom the ~ront.
Re~erring to Figure 3, metal i9 sputtered on the baak surface o~ the gla~s throughout a region 25 which surrounds an area 26 that 18 free of metallization and dallneates the letter T; alternatively, the metal may be sputtered onto the glasq throughout the area 26 leaving the region 25 clear. In the ~irst case, the view from the ~ront of the panel wlll show the letter T
in aolor against a mirror background, where the powder-~ 33270 1 coating on the back surface shows through the area 26,whereas in the second case, the letter T will appear ln mirror form against the color background of the region 25.
The delineatlon of the letter T in the case of Figure 3, may, instead, be carried out at the powder-deposition stage of production by f$r~t depositing a powder of one pl~mentation to cover the region 25 or She area 26, and then a powder of another pigmentation to cover the other; stencils may be used for achieving the required dalineation of the different powder~. The letter T will then be seen in dis-tinctive color against a colored background in the finished panel.
Color and other dscorative efect in the glass need not be dependent wholly or partially on pigmentatlon o~ tha powder coating. In partiaular, the pigment may be omitted from the coating powder ln the panel o~ Figure l, so as to result in a substantially transparent coating 2 which exposes the ~oil 4 to view ~rom the ~ront of the gla~s sheet 1. Thus color and/or other decorative e~fect in the glass 1~ realised in this case by what i8 visi~le on the bonded sur~ace o~ the ~oil 4:
thls sur~aae is readily aolored and/or otherwi~e decorated (~or example, prior to supply to the ~oil-appliaatlon station 17 o~ the produation llne o~ Flgure 2), and use o~ thls technique ls o~ signi~iaantly wide potential appliaat:lon. Where the bonded sur~aae is polished, a mirror e~ect i8 achlevad, and any aolor o~
that sur~aae i8 then lnaorporated into the mirror.
~he present invention, although particularly advantageous in the aontext of the provislon of glass-~aced panels for architectural or other purposes, isnot llmited to this context: an example of its wider applicatlon is lllustrated, for example, in Flgure 4, ..
t 33270 1 which illustrates the ~ormation and application of decals to a powder-coated article. In particular, as illustrated in Figure 4, the decals themselves, may be of thermosetting powder-coating material.
Figure 4 illustrates the manner in which a decal in the shape of the letter T is derived and transferriod to become part of the finished article.
Re~erring to Figure 4, a thermosetting organic coating-powder, ~or example of an epoxy or polyester resin, is first laid down on a substrate 31 and is then cured to form a coating 32. The ~ubstrate 31, for example of polytekrafluorethylene, is chosen (or is otherwise treated) to be such that the coating 32 readily strips from it, and in particular such that an element 33 having a desired shape - which in the illustrated case is that of the letter T - can be cut from the coating 32 and removed. The element 33 is now used to provide ~0 the letter ~ as a decal on the upper face of a base member 34 of glass.
In the latter respect, the base member 34, after being treated with an adhesion promoter lf neaessary, ii3 ~5 coated with a thermosetting organic coatlng-powder;
this may be the same as that used for the coating 32 but with di~ferent pigmentatlon. ~he nlember 34 is now heated to melt the powder, and the element 33 i9 ~hen applled to ~he melt in the location appropriate Por,the decal on the base member 34. Finally, after curing the powder, the whole is allowed to cool, leaving the element 33 firmly bonded in place on the now-formed coating of the base member 34.
The technique described with re~erence to Figuxe 4 has ad~antage in that the decal element 33 is firmly secured to the coated member 34 without the use of any `B : -1 33270 ~
adhesive, and resists attack by weather and wear.
Also, a very distinctive effect can be obtained simply by using different pigments in the powders of coatings 32 and 35.
Where clear glass is used as the base member 34, the technique described with reference to Figure 4 may be modified to provide for viewing of the decal through the glass. The element 33 is in this case placed on the upper surface of the glass and the uncovered areas oP that surface then treated with silane before the powder is applied over those areas and the element 33.
Heating melts the powder and brings about full contact between it and the element 33, so that after further heating to cure the powder and subsequent cooling, the element remains firmly bonded in the coating.
The method of the present invention may be applied as illustrated in Figures 5 and 6, to the bonding of glass over an aperture in a metal wall, and to the formation of a glass laminate, respectively. `
Referring to Figure 5, a glass sheet 36 is located over an aperture 37 in a metal wall 38, the sheet being bonded to the wall 38 by cured powder-coating material 39; the aoating 3g is shown con~ined to the margin o~
the aperture 37, but clearly it could extend aGross the whole o~ the wall fac~. In manu~aature oP this article, th~ cont~atlng face o~ the sheet 36 i~
lnitially provided with a coat 40 of a silane adhesion-promoter, and an epoxy or other coating powder is applied around (at least) the margin of the aperture 37 of the wall 38. The powder is now heated to the melt phase, and the glass sheet 36 is placed over the aperture 37, silane-coated face down, into surface contact With the melt around the aperture margin. The sheet 36 is retained in this condition while the ,:
' '~B .~
. .
~ 33270 1 assembly is heated further to cure the powder and form the coating 39 bondiny the glass sheet 36 to the wall 38, over the aperture 37.
In the example of Figure 6, two glass sheets ~1 and 42, which have coats 43 and 44 respectively, of a silane adhesion promoter, are bonded together as a laminate by means of a polyester or other powder coating 45. Such a laminate is applicable, for example, where color but opacity, or at least translucency, is required with glass Eacing on both sides of the laminate.
Manufacture is carried out by applying the powder for the coating 45 to the silane-prepared face of one of the sheets 41 and 42, melting the powder, contacting the melt across the whole area with the silane-prepared ~ace of the other sheet, and maintaining such contact while the powder is cured. The likelihood of entrapping gas in the laminate can be reduced, by carrying out the steps of establishing contact of the glass with the melt, and also curing the powder, within a reduced-pressure atmosphere.
The thermosetting organic powder-coating material5 that are suitable ~or use in the various embodiments o~ the invention de~cribe~ above, include polyester, epoxy-, aarylic- and polyurethane-based powders. Such powder9 may include, as well a~ pigmenta where appropria~e, extender~ in thq form oP mineral Piller~, and flow modiPiers.
The use of polyester/triglycidyl-isocyanurate powders has been described in the context of the embodiment of Figure 1, but as an alternative, a polyester resin with an epoxy curing agent may be used. The catalyst included may be typically choline chloride, stannous octoate, or tetrabutylammoniumbromide to a level typically from 0 to 0.2 per cent. Furthermore, an ~ B
.
epoxy resin with a dicyandiamide curing agent may be used. All such powders may find application in the other embodiments described.
As regards adhesion promoter, the use of a silane, and in particular gamma-mercaptopropyltrimethoxysilane, is referred to in connection with the embodiment of Figure 1. As an alternative, gamma-aminopropyltriethoxysilane may be used, and these adhesion promoters are also applicable in the other embodiments described.
~ '' ' . ~
1 ~32.7~
Articles that include Glass ~hee~n~
This invention relates to articles that include glass sheeting.
The invention is particularly concerned with articles of the kind that include a bond between a glass sheet and another component, and especially with methods of manufacturing such articles.
'~'`
According to one aspect of the present invention, there is provided a method o~ manufacturing an article that includes a bond between a glass sheet and another component of the manufactured article, wherein the bond is formed by thermosetting organic powder-coating material, the powder being heated to melt it in contact with a surface of one of the components, and wherein, prior to curing and while the powder is in a melted ~0 condition, contact is established between the melted powder and a sur~ace of the other component, and such contact is maintained during curing so as to ~orm said bond.
: .
~-~ 25 l'hermosetting organic powders are known in the context o~ the manufacture oP, ~or example, panels ~or doors, partitions and other purposes in whiah at lea~t the ~ront sur~aae o~ a sheet o~ metal that i~ to provide the eacing ~heet oP the pan~l, is aoated evenly with an 30 epoxy or other ~hermosetting organic powder.l Stoving ~
then takes place to heat the powder to a kemperature at `
.
which it melts and cures so as to form, on cooling, a hard protective face-coating to the metal sheet. The~ ;~
coating af~ords protection to the metal, and pigmentation in the powder can be used to give color ~or decorative ef~ect.
`: :
13~2701 It has been found that the known powder-coating technique can be extended to achieve a bond with glass sheeting that is of particularly advantageous effect.
Using the method according to the present invention, a very firm bond between a glass sheet and another component o~ the manufactured article can be achieved via the coating.
Thus, not only can the advantages o~ the powder coating be realised ~or protective and/or decorative effect, but they can be combined with the advantage of the adhesive efPect. More especially, it has been found that the invention is of significant advantage in the provision o~ glass cladding for both exterior and interior architectural purposes.
In the latter respect, the coating is advantageously applied to the back sur~ace of the glass, so that `~
whether the glass iisi clear or otherwise, pigmentation o~ the coating is revealed throuyh the glass to give ~I the ePfect o~ color in the glass. Where no pigmentation is used, and/or depending on the transparency of the coating, the component bonded to .
~he back of the coatiny may also contribute to the ~5 vlsual e~Pect in the ylass.
~lowever, even where coloration or other decorative e~ect is not sought, particular advantage ls obtainable in another re~pect 1~ the backing aomponent bonde`d with thelcoating is o~ thèrmally conduativèl ma~erial, for example aluminium ~oil, and covers the~ `
coating surface to a~substantial~extent, siince such component will then have the effect of tending to e~uaIize temperature across the glass sheet. This facilitates the use of annealed glass in contexts where it would not o~herwise be acceptable or possible to use ~ , ;`;
."' ' .
1 332701 ~: `
it, in particular for architectural colored-glass cladding.
The glass conventionally used for architectural 5 cladding, is toughened, and this precludes cutting to ;
size, and ease of fitting, on site; toughened glass is used in order to withstand temperature gradients, and also to resist impact without splintering dangerously.
Use o~ annealed glass instead o~ toughened, would be prePerred, since such glass is cheaper and can be cut on site, but annealed glass does not in general withstand temperature gradients and provide adequate resistance to impact, within the normal sa~ety criteria.
The present invention makes it possible for this pre~erence to be exerclsed, in particular because the use oP a thermally-conductive sheet as the component bonded to the back of the powder coating applied to the ; 20 glass, can be e~Pective to reduce temperature gradients ~ ;
across the glass to an extent adequate to allow annealed qlass to be used in a wide range o~
~ architectural environments. ;
;~ ~5 The Pact that color or other decorative e~Pect can readil~ be provided, as rePe~red to abov~, in ~uch gla~, ha~ an additional advantage in thi~ context, ~lnce r~uire~ent Por color or other decorative e~ect inl claddingllglass would normallylmake ulse o~ltoughlened glass essential.
Thus, according to a ~eature of the present invention, in a method~o~ manufacturing a panel ~or architectural or other purpose, in which a thermosetting organic powder-coating material applied to a surfaae o~ a Pacing ~heet oP the panel is heated to melt and cure the powder and thereby form a coating bonded to the .~ ~'.` .
' ! ,;. '~
surface, the facing sheet is a glass sheet, the coating is applied to the back of the glass sheet, and, prior to curing and while the powder is in the melted condition, contact is established between the melted powder and a surface of a thermally-conductive sheet, such contact being maintained during curing so that the sheet is thereby bonded, as a thermally-conductive backing, with the cured powder coating.
This feature of the present invention is applicable to toughened glass as well as to annealed glass, but, as indicated above, the application to annealed glass has special advantage.
.:
Resistanae to impact and thermal shock o~ the glass can be enhanced to a very substantial degree - especially where annealed glass is used - by bondinq an open-cell material in the form, for example, of a flexible and compressible ~oamed plastics or rubber layer, to the backing sheet. A rigid board of, for example, wood or foamed plastics, may be bonded behind this latter layer to give added strength to the panel.
In the method of the present invention as presented generally and ~pecifically above, an adhesion pxomotar m~y b~ used to pr~-coat the surface that i~ to receive ; applioation ~or example, electrostatically) o~ the powder-coating material. ~he pro~oter ~ay be a 9ilane, and in ~hi~ re~peot may be applied as a solutlon o~ the silane in~a blend o~ water with isopropanol or another alcohol. The silane may be an organosilane ester.
The invention also relates to articles produced according to the methods of the present invention as these are referred to in the general and specific terms set out above.
B
1 3327n ~
5 73062~
More especlally, and according to another aspect of the ~;;
present invention, there is provided a panel ~or architectural or other purpose, in which a facing sheet o~ the panel carries a coating of cured thermosetting organic powder material, wherein the facing sheet is a glass sheet, the coating backs the glass sheet, and the coatlng ls backed by a sheet that is bonded to the ~
ylass sheet by the cured powder material o~ the coating. ~;
The coating may be pigmented to show color in the glass faaing, and the backlng sheet may be thermally-conductive;
aluminium ~oil may be used with advantage in this respect. ;
Furthermore, open-cell material, ~or example in the form of a ;`
layer o~ flexible and compressible foamed plastics or rubber, may be bonded to the backing sheet.
Examples of articles and methods of their manufacture in accordance with the present invention, will now be described, wlth reference to the accompanying drawings, in whiah, Figure 1 is a pexspeative view of part o~ an architeatural panel ln accordance with the present lnvention;
Figure 2 is a sahema~ia representation o~ par~ o~ a produ~tion line ~or manu~acturing the architeatural panel o~ `
Figure 1 using a method aacordin~ ~o the present invention~
~ Flg,ure 3 i8 illlustratjive~o~ modi~ication~o~ the panel,o~;
Figure l;
Figure 4 illustrates another method of manufacture according ;~
~; to the present invention; and ~ , .. ..
::
Figures 5 and 6 are sectional side-views of further articles that in both their structure and method of manufacture, are in accordance with the present invention.
~ :
The architectural panel to be described with reference to Figure 1, is of a form suitable for use in providing glass cladding to exterior or interior walls of ::
buildings. For this application, the panel is rectangular with glass-face dimensions of some 3 x 1.2 metres, and an overall thickness of some twenty-eight "
~ .
7 137)~701 millimetres; clearly panels of larger or smaller dimensions can be provided.
Referring to Figure 1, the panel is faced by a sheet 1 of clear, annealed glass having a thickness of 4 millimatres. The glass sheet 1 is backed by a cured polyester powder-coating 2 bonded to the sheet 1 via an interlayer 3 of silane adhesion-promoter. The interlayer 3 is very thin (perhaps only one molacule thick), and the coating 2, which has a thickness in the range rom 60 to 120 microns, con-tains a pigment to show color in the glaqs facing and give the visual efeat o colored glass to the cladding panel.
The coating 2 has a backing o~ aluminium foil 4 that is bonded to the sheet 1 via the coating 2 ln the process of stoving the polyeQter powder-coating 2 on the glass sheet 1. The foil 4 has a nominal thickness of 0.1 millimetre, and being of good thermal conductivity, serves to equalize tamperature variations across the panel. The function of the foil 4 in this latter regard is important in the context of the use o~
annealed glass, which 18 less reslstant to temperature gradlents than toughened glass, especlally in exterior applicatlon~ where part of the panel may be in sunlight and part in shadow. ~owever, the ~oil 4 al~o has a protective ~unotion in relation to the general porosity o~ tha coating 2, the foil ~ in this regard proteating the coating 2 again~t degradation ~rom moisture and weathering generally;~ ~he nature o~ the intlmate bond obtained aoaording to the invention, between the coating 2 and the foll 4, without the need for introduation of an adhesive interlayer between them, is espealally advantageous.
Even to the llmited extent that the panel of Figure 1 has so far been described, it ls capable o~ being used ~or oladdlng purposes, whether in the ~orm o large sheets as described, or smaller tilas. In particular, the use of annealed glass enables the panel to be readily cut to size on site, but the usefulness of the panel, in particular its capabillty of resisting impact and thermal shock, is greatly enhanced by the addition, as illustratad in Figure 1, of an element 5 of flexible and compressible open-celled foamed plastics or rubber material, bonded to the back of the alumlnium foil ~.
The element 5 is in the Porm of a layer of some 3 millimetres in thickness, and has both faces aovered by layers 6 and 7 of finely-woven or knitted nylon mesh that has been flame-welded to the layer 5; the mesh serves to stabilize the layer during its bonding into the panel. A rigld board 8 o~ fo~med polyurethane and/or polyisocyanurate or phenolic resin, ~aaed with sheets 9 and 10 of aluminlzed paper or glass ~ibre, is bonded to the element 5 via the facing layer 7, to add rigidity and further damage-protection to the panel without detraating from the ease of outting and fitting on site.
As lndicated above, the foil 4 has a ~ignificant effect in e~uali~ing temperature variation3 acro~s the panel, as well as providing protectlon ~or the aoating 2.
Incorporatlon o~ the open-cell element 5 lnto the panel to back the ~oll 4, not only signi~i¢antly enhance~ the ~esi~tance of the glass to lmpaot, but al~o adds ~urther ~o its ability to withstand temperature di~erential between ad~acent arqas of the glass. The open-cell str~ature,tend~ to promote the disp~rsion of haat aoross the glass, and thereby tends to reduce temperature gradients, by retarding movement of hot gas away ~rom the foil 4 and enhanoement of lts movement across the baok of the panel.
~ests with annealed gla~s have lndicated that the aapaaity o~ the glass to withstand temperature di~erential was increased by some 80 to 90 degrees -1 3:~701 Cel~lus when provided with the coating 2 and its foil 4 backed by the element 5. Furthermore, such tests have shown that as well as greatly increasing lmpact resistance of the glass, the construction reduces significantly the extent of splintaring when the glass does eventually break.
~he method o~ manufacturlng the panel wlll now be described with raference to Figure 2, which lllustrates part of a production line for manu~acturing panels o~
the form shown in Figure 1, in a continuous process.
The manu~acturing process will be described, and the production line is illustrated in Figure 2, only up to the stage at which the glass sheet 1 has been provided with the cured coating 2 and its aluminium foil-backing. The addition of the layer-element 5 and board 8, is carried out ln essentially the same manner as the provislon o~ like layer~ and boards for mirrors, desoribed in U~ Patent No 2,048,166, and will not be descrlbed here.
Referring to Figure 2, the sheet 1 of gla88 iS loaded face down on a conveyor at the first s-tation 11 o~ the productlon line, and is transerred by the conveyor tQ
a aleaning statlon ~2 where all loose debris i9 removed ~rom both ~aces oP the sheet 1 by means o~ a vacuum cleaner. The sheet 1 then paq~e~ on the conveyor throuyh a washin~ station 13 where i't8 upper, back, sur~ace i~ ~prayed with a solution o~ isopropanol and distilled water,i and scruhbed by rotatlng brùshes to remove all dirt, before bein~ wiped or air-blown dry of excess solution.
From the washing station 13, the glass sheet 1 passes lnto a spray statlon 14 where the upper sur~ace o~ the sheet 1 is sprayed with a ~ine mist o~ a solution of silane in a blend of isopropanol and dlstilled water.
As the sheet 1 leava~ the station 14, warm air is lo 13~70~
directed at the glass to dry the glass surface and leave it coated with the thln interlayar 3 of silane, before the sheet 1 passes to the next, powder-deposit station 15.
The station 15 includes provlslon for electrostatic or tribostatic deposition of polyester powder-coating material on the silane-coated upper surface of the 3heet l. The powder, which i8 the milled product of extruding a melted mixture o~ a polyester resin, cross-llnklng agents and pigments, is deposited on the upper sur~ace o~ the sheet 1 evenly, and to a depth within the range 60 to 120 microns, by regulating the uni~ormity and speed of progress of the sheet 1 through the station 15. As the sheet 1 leave~ the station 15, the lower, front face of the glass is brush- and vacuum-cleaned to ensure that none of the powder remainq on this Pace.
~he sheet 1 now enters a melt station 16 where infra-red heater~ maintain a temperature in the range 150 to 170 degree~ Celsiu~, so as to melt the powder, The heat is applied uniformly across the whole body o powder for a period o~ some two mlnute~ before the sheet 1 moves to a foil-application station 17 ~or reaeivlng the ~heet of aluminium foil 4. In thls regard, ~oil i8 di~pensed from a supply roll ~not shown) onto the melted powder vla heated siliaone-coatQd rollers 1~ and 19; the heatirly of the rollers 18 and 19 i~ su~fialent to,avoid any aonden~ation on ~the ~oil. The sheet 1 is ~topped momentarily as the leading edge of the foil is brought down onto the leadlng edge of the melt under a roller 20, and is then carried forward with the foil pressed downwardly by the roller 20 into sur~ace contact with the laysr of melted powder. The downward pres~ure is maintained a~ the foil is fed at an angle onto the moving melt-surface under the roller 20, so as to ensure that air which ;
~3~270~
would otherwise be entrapped under the foil, iis squeezed out. When the whole of the melt is covered, the sheet 1 stops momentarily again to allow a flying knife 21 to cut the ~oil at the trailing edge. This divides o~ from the supply web the elament of foil, namely the foil 4, that now lies in full surface contact wlth the body of melted powder, and enables the sheet 1 to move out of the station 17 into a curing ~tation 22.
The alr temperature within the curing station 22 lies wlthin the range o~ 210 to 230 degrees Celsius, so as to raise the temperature o~ the assembly o~ sheet 1, melted powder and foil 4, to some 200 degrees Cel~lus.
The assembly i.s maintained at this level o~ temperature for ten mlnutes, in order to cure the powder and affect the bonding to the sheet 1 and foil 4. A~ter thls, the sheet 1 wlth its cured coating 2 and adharing foil 4, pass lnto a cooling station 23 and thence to an ~0 unloading station 24 for subsequent attachment o~ the backing element 5 and board 8, as required.
It has been found that the ~ured powder-coating provides not only good ooloration (aacording to th~
partlcular pigmentatlon used in the powder) ~or the vlsual ef~eat ln the glass, but also a strong bondlng between the glass and the foil 4. Moraover, the manu~acturing me~hod described, has been .~ound to result in a product whioh is ~ree rom air bubbleis and rlpples betwe~nlthe glass and coating, and between the coating and foil ~, and for which the color-view in the glass ls uniform and wlthout blemish, aoross the full area o~ the ~ront ~ace of the panel. Reduction in the po~slbllity o alr or other gas bubbles afectlng the coating can be achieved i~ the meltlng and curlng stages o~ the method are carried out in a reduced-pressure or partial-vacuum atmosphere.
- . . , . , . " . . . . ... .. . .... .... . ...... . . ......... ..
The particular powder-coatlng material preferred for use in the context of the panel described above, is a polyester resin containing a catalyst agsnt with a triglycidyl isocyanurate curing agent; the powders sold as PPL858G and PPH857G under the trade mark DURAPLAST
by Holden Surface Coatings Ltd. of Birmingham, England, are appropriate in this respect. Such powders provida structures that not only have good bondlng, but have also been found to be markedly reslstant to the e~fects o~ humidlty and o~ salt, sulphur dioxide and other pollutants in the atmosphere, and to sunlight.
Although the polyester/triglycidyl-isocyanurate powders have been found advantageous in the above context, other polyester powders, and epoxy-, acrylic- and polyurethane-based powders, may be applicable in appropriate circumstances. Powders combining a polyester resln with an epoxy curing agent have, in particular, been found to provide acceptable results.
~0 The use o~ an adhesion promoter on the glass is desirable to ~acilitate a good bond wlth the powder coating; as lndicated above, a sllane has been use~ ~or thi~ purpose. More especlally, it ha~ been found that an or~ano~ilane ester ~aallitates good bondin~ when applied in a solution contalning 3 per cent by volume o~ the silane in a blend o~ isopropanol and distllled water ~or whlah the ratio o~ isopropanol to water is 4:1 by Yolume~ Gamma-mexaaptopropyltrimethoxy~ilane ha~ been ~oun~ ~spea~ally e~eotive when used ln this way; the produat sold under the Trade Mark UNION
CARUIDE as Organofunctional Sllane A-189 by Union Carblde Corporation ls appropriate in thi~ respect.
The foil used to back the powder aoatin~ i preferably an alumin~um-alloy foil o~ hard temper that has been pre-treated by the rlnse method with a mlxed alumlnium phosphate and chromlum III phosphate prlmer. The use of a hard temper facilitates easy and clean cutting of the panel.
Various decorative effects beyond uniform coloratioQ, can be readily obtained with a glass-~aced panel constructed in the general manner described with reference to Figure 1. In partlcular, a combined mirror and color effect can be achleved by sputtering or otherwise depositlng a thin layer o~ metal on part or parts o~ the back sur~ace of the glass prior to coating lt with powder (~or exampl0, prlor to entry into station 14 of the production line illustrated in ~lgure 2); the metallized part or par-ts give a mirror e~fect with the pigmentation of the cured powder-coating showing in the glass elsewhere. Alternativelyor in addltion, di~erent pigmentations may be used in difPsrent-areas, simply by ~epositing the di~farently-pigmented powder~ on the back surface of the glass where required (~or example, within station 15 o tha production line illustrated in Figure 2); there is minimal di~usion o~ pigmentation across the interface between powders during the melt and curing phases.
Either (or both) o~ these technlques may be applied, ~or example, to the provision o~ dlstinative let-tering or other s~mbology in the glass, ais will now be d~aribed with re~erence to Figure 3 which lllu~trate~
the letter ~ aY thls i8 both delineated on part of the baa~ sur~ace o~ the glass and i8 vislblo in the gla~s ~rom the ~ront.
Re~erring to Figure 3, metal i9 sputtered on the baak surface o~ the gla~s throughout a region 25 which surrounds an area 26 that 18 free of metallization and dallneates the letter T; alternatively, the metal may be sputtered onto the glasq throughout the area 26 leaving the region 25 clear. In the ~irst case, the view from the ~ront of the panel wlll show the letter T
in aolor against a mirror background, where the powder-~ 33270 1 coating on the back surface shows through the area 26,whereas in the second case, the letter T will appear ln mirror form against the color background of the region 25.
The delineatlon of the letter T in the case of Figure 3, may, instead, be carried out at the powder-deposition stage of production by f$r~t depositing a powder of one pl~mentation to cover the region 25 or She area 26, and then a powder of another pigmentation to cover the other; stencils may be used for achieving the required dalineation of the different powder~. The letter T will then be seen in dis-tinctive color against a colored background in the finished panel.
Color and other dscorative efect in the glass need not be dependent wholly or partially on pigmentatlon o~ tha powder coating. In partiaular, the pigment may be omitted from the coating powder ln the panel o~ Figure l, so as to result in a substantially transparent coating 2 which exposes the ~oil 4 to view ~rom the ~ront of the gla~s sheet 1. Thus color and/or other decorative e~fect in the glass 1~ realised in this case by what i8 visi~le on the bonded sur~ace o~ the ~oil 4:
thls sur~aae is readily aolored and/or otherwi~e decorated (~or example, prior to supply to the ~oil-appliaatlon station 17 o~ the produation llne o~ Flgure 2), and use o~ thls technique ls o~ signi~iaantly wide potential appliaat:lon. Where the bonded sur~aae is polished, a mirror e~ect i8 achlevad, and any aolor o~
that sur~aae i8 then lnaorporated into the mirror.
~he present invention, although particularly advantageous in the aontext of the provislon of glass-~aced panels for architectural or other purposes, isnot llmited to this context: an example of its wider applicatlon is lllustrated, for example, in Flgure 4, ..
t 33270 1 which illustrates the ~ormation and application of decals to a powder-coated article. In particular, as illustrated in Figure 4, the decals themselves, may be of thermosetting powder-coating material.
Figure 4 illustrates the manner in which a decal in the shape of the letter T is derived and transferriod to become part of the finished article.
Re~erring to Figure 4, a thermosetting organic coating-powder, ~or example of an epoxy or polyester resin, is first laid down on a substrate 31 and is then cured to form a coating 32. The ~ubstrate 31, for example of polytekrafluorethylene, is chosen (or is otherwise treated) to be such that the coating 32 readily strips from it, and in particular such that an element 33 having a desired shape - which in the illustrated case is that of the letter T - can be cut from the coating 32 and removed. The element 33 is now used to provide ~0 the letter ~ as a decal on the upper face of a base member 34 of glass.
In the latter respect, the base member 34, after being treated with an adhesion promoter lf neaessary, ii3 ~5 coated with a thermosetting organic coatlng-powder;
this may be the same as that used for the coating 32 but with di~ferent pigmentatlon. ~he nlember 34 is now heated to melt the powder, and the element 33 i9 ~hen applled to ~he melt in the location appropriate Por,the decal on the base member 34. Finally, after curing the powder, the whole is allowed to cool, leaving the element 33 firmly bonded in place on the now-formed coating of the base member 34.
The technique described with re~erence to Figuxe 4 has ad~antage in that the decal element 33 is firmly secured to the coated member 34 without the use of any `B : -1 33270 ~
adhesive, and resists attack by weather and wear.
Also, a very distinctive effect can be obtained simply by using different pigments in the powders of coatings 32 and 35.
Where clear glass is used as the base member 34, the technique described with reference to Figure 4 may be modified to provide for viewing of the decal through the glass. The element 33 is in this case placed on the upper surface of the glass and the uncovered areas oP that surface then treated with silane before the powder is applied over those areas and the element 33.
Heating melts the powder and brings about full contact between it and the element 33, so that after further heating to cure the powder and subsequent cooling, the element remains firmly bonded in the coating.
The method of the present invention may be applied as illustrated in Figures 5 and 6, to the bonding of glass over an aperture in a metal wall, and to the formation of a glass laminate, respectively. `
Referring to Figure 5, a glass sheet 36 is located over an aperture 37 in a metal wall 38, the sheet being bonded to the wall 38 by cured powder-coating material 39; the aoating 3g is shown con~ined to the margin o~
the aperture 37, but clearly it could extend aGross the whole o~ the wall fac~. In manu~aature oP this article, th~ cont~atlng face o~ the sheet 36 i~
lnitially provided with a coat 40 of a silane adhesion-promoter, and an epoxy or other coating powder is applied around (at least) the margin of the aperture 37 of the wall 38. The powder is now heated to the melt phase, and the glass sheet 36 is placed over the aperture 37, silane-coated face down, into surface contact With the melt around the aperture margin. The sheet 36 is retained in this condition while the ,:
' '~B .~
. .
~ 33270 1 assembly is heated further to cure the powder and form the coating 39 bondiny the glass sheet 36 to the wall 38, over the aperture 37.
In the example of Figure 6, two glass sheets ~1 and 42, which have coats 43 and 44 respectively, of a silane adhesion promoter, are bonded together as a laminate by means of a polyester or other powder coating 45. Such a laminate is applicable, for example, where color but opacity, or at least translucency, is required with glass Eacing on both sides of the laminate.
Manufacture is carried out by applying the powder for the coating 45 to the silane-prepared face of one of the sheets 41 and 42, melting the powder, contacting the melt across the whole area with the silane-prepared ~ace of the other sheet, and maintaining such contact while the powder is cured. The likelihood of entrapping gas in the laminate can be reduced, by carrying out the steps of establishing contact of the glass with the melt, and also curing the powder, within a reduced-pressure atmosphere.
The thermosetting organic powder-coating material5 that are suitable ~or use in the various embodiments o~ the invention de~cribe~ above, include polyester, epoxy-, aarylic- and polyurethane-based powders. Such powder9 may include, as well a~ pigmenta where appropria~e, extender~ in thq form oP mineral Piller~, and flow modiPiers.
The use of polyester/triglycidyl-isocyanurate powders has been described in the context of the embodiment of Figure 1, but as an alternative, a polyester resin with an epoxy curing agent may be used. The catalyst included may be typically choline chloride, stannous octoate, or tetrabutylammoniumbromide to a level typically from 0 to 0.2 per cent. Furthermore, an ~ B
.
epoxy resin with a dicyandiamide curing agent may be used. All such powders may find application in the other embodiments described.
As regards adhesion promoter, the use of a silane, and in particular gamma-mercaptopropyltrimethoxysilane, is referred to in connection with the embodiment of Figure 1. As an alternative, gamma-aminopropyltriethoxysilane may be used, and these adhesion promoters are also applicable in the other embodiments described.
~ '' ' . ~
Claims (30)
1. A method of manufacturing an article that includes a bond between a glass sheet and another component of the manufactured article, wherein the bond is formed by thermosetting organic powder-coating material, the powder being heated to melt it in contact with a surface of one of the components, and wherein, prior to curing and while the powder is in a melted condition, contact is established between the melted powder and a surface of the other component, and such contact is maintained during curing so as to form said bond.
2. A method according to Claim 1 wherein said other component is of metal.
3. A method according to Claim 1 wherein said other component is of glass.
4. A method according to Claim 2 or Claim 3 wherein said other component is of sheet form, and this sheet is brought into, and maintained in, surface contact With the melted powder.
5. A method according to Claim 1 wherein said other component is an element of cured surface-coating material.
6. A method according to any one of Claims 1 to 3 wherein the surface of said one component is coated with an adhesion promoter prior to application of the powder thereto.
7. A method according to any one of Claims 1 to 3 wherein the thermosetting material includes pigmentation to color the cured coating.
8. A method of manufacturing a panel for architectural or other purpose, in which a thermosetting organic powder-coating material applied to a surface of a facing sheet of the panel is heated to melt and cure the powder and thereby form a coating bonded to that surface, wherein the facing sheet is a glass sheet and the coating is applied to the back of the glass sheet, and wherein, prior to curing and while the powder is in the melted condition, contact is established between the melted powder and a surface of a thermally-conductive sheet, such contact being maintained during curing so that the sheet is thereby bonded, as a thermally-conductive backing, with the cured powder coating.
9. A method according to Claim 3 wherein the thermally-conductive backing sheet is of aluminium.
10. A method according to Claim 8 wherein the powder-coated glass surface is coated with an adhesion promoter prior to application of the powder-coating material.
11. A method according to Claim 10 wherein the adhesion promoter is a silane.
12. A method according to Claim 11 wherein the silane is applied in solution with an alcohol-water blend.
13. A method according to Claim 11 or Claim 12 wherein the silane is an organosilane ester.
14. A method according to any one of Claims 8 to 12 wherein the thermosetting material includes pigmentation to give a visual effect of color in the glass.
15. A method according to any one of Claims 8 to 12 wherein the step of applying the powder coating material involves the application of powder-coating materials having different pigmentations to different locations of the glass surface, such as to give the effect of different colors in different parts of the glass.
16. A method according to any one of Claims 8 to 12 wherein pigmentation is omitted from the thermosetting material so that at least part of the coating-bonded surface of the backing sheet is viewable in the glass, through the coating.
17. A method according to any one of Claims 8 to 12 wherein at least part of the glass surface is metallized.
18. A method according to any one of Claims 8 to 12 wherein the powder is applied to the back of the glass sheet electrostatically .
19. A method according to any one one Claims 1 to 3 or any one of Claims 8 to 12 wherein the thermosetting material includes a polyester resin.
20. A method according to any one of Claims 1 to 3 or any one of Claims 8 to 12 wherein the thermosetting material contains a polyester resin and a catalyst agent with a triglycidyl isocyanurate curing agent.
21. A panel for architectural or other purpose, in which a facing sheet of the panel carries a coating of cured thermosetting organic powder material, wherein the facing sheet is a glass sheet, the coating backs the glass sheet, and the coating is backed by a sheet that is bonded to the glass sheet by the cured powder material of the coating.
22. A panel according to claim 21 wherein the sheet backing the coating is a thermally-conductive sheet.
23. A panel according to claim 22 wherein the thermally-conductive sheet is of aluminium.
24. A panel according to claim 21 wherein open-cell material is bonded to the backing sheet.
25. A panel according to claim 24 wherein the open-cell material is a layer of flexible and compressible foamed plastics or rubber.
26. A panel according to any one of claims 21 to 25 wherein the coating is pigmented to show color in the glass facing.
27. A panel according to any one of claims 21 to 25 wherein the coating is substantially transparent so that at least part of the coating-bonded surface of the backing sheet is viewable in the glass, through the coating.
22a
22a
28. A panel according to any one of claims 21 to 25 wherein the back surface of the glass facing sheet carries reflective material on at least part of that surface to provide a mirror effect therefrom in the glass facing.
29. A panel according to Claims 21 wherein the thermosetting material includes a polyester resin.
30. A panel according to Claim 29 wherein the thermosetting material contains a catalyst agent with a triglycidyl isocyanurate curing agent.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB878716242A GB8716242D0 (en) | 1987-07-10 | 1987-07-10 | Powder coated panels |
| GB8716242 | 1987-07-10 | ||
| GB8815638A GB2207089B (en) | 1987-07-10 | 1988-06-30 | Articles that include glass sheeting |
| GB8815638 | 1988-06-30 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1332701C true CA1332701C (en) | 1994-10-25 |
Family
ID=26292463
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000571528A Expired - Lifetime CA1332701C (en) | 1987-07-10 | 1988-07-08 | Articles including thermosetting-powder surface-coatings |
Country Status (5)
| Country | Link |
|---|---|
| US (2) | US5089076A (en) |
| AU (1) | AU607782B2 (en) |
| CA (1) | CA1332701C (en) |
| IE (1) | IE60859B1 (en) |
| NZ (1) | NZ225331A (en) |
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|---|---|---|---|---|
| IE60859B1 (en) * | 1987-07-10 | 1994-08-24 | Ici Plc | Articles that include glass sheeting |
| GB8918637D0 (en) * | 1989-08-15 | 1989-09-27 | Chelsea Artisans Plc | Articles including thermosetting-powder surface-coatings |
| US5558827A (en) * | 1991-12-16 | 1996-09-24 | Howes; Stephen E. | Decorative window having simulated came structure |
| US5783264A (en) * | 1991-12-16 | 1998-07-21 | Howes; Stephen Edwin | Decorative windows with contoured plastic resin laminated to glass |
| ATE145195T1 (en) * | 1992-07-11 | 1996-11-15 | Pilkington Uk Ltd | METHOD FOR PRODUCING REFLECTIVE LAYERS ON GLASS AND MIRRORS PRODUCED BY THIS METHOD |
| GB9400320D0 (en) * | 1994-01-10 | 1994-03-09 | Pilkington Glass Ltd | Coating on glass |
| GB9400319D0 (en) * | 1994-01-10 | 1994-03-09 | Pilkington Glass Ltd | Coatings on glass |
| GB9400323D0 (en) * | 1994-01-10 | 1994-03-09 | Pilkington Glass Ltd | Coatings on glass |
| SE9504460D0 (en) * | 1995-12-13 | 1995-12-13 | Herberts Powder Coatings Ab | Process for bonding and adhesive composition for use in the process |
| GB9821983D0 (en) * | 1998-10-08 | 1998-12-02 | Thorstone Business Man Ltd | Panels |
| GB9821991D0 (en) * | 1998-10-08 | 1998-12-02 | Thorstone Business Man Ltd | Coatings |
| US6316099B1 (en) | 1999-03-31 | 2001-11-13 | 3M Innovative Properties Company | Multi-layered sealant |
| GB9923908D0 (en) * | 1999-10-08 | 1999-12-08 | Thorstone Business Man Ltd | Foam laminates |
| US6313448B1 (en) | 1999-10-21 | 2001-11-06 | 3M Innovative Properties Company | Adhesive bonding method and device |
| US6455148B1 (en) | 2000-07-07 | 2002-09-24 | Reynolds Metals Company | Composite panel with a foamed plastic core |
| DE10332052A1 (en) * | 2003-07-15 | 2005-02-03 | Heinrich Strunz Gmbh | Process for the production of a laminate, apparatus for carrying out the process and obtained laminate |
| GB0404655D0 (en) * | 2004-03-02 | 2004-04-07 | Thorstone Business Man Ltd | Glass products |
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| US2549893A (en) * | 1945-02-28 | 1951-04-24 | Cook Harold | Reflective sign |
| US2468568A (en) * | 1945-09-27 | 1949-04-26 | Safetee Glass Company | Laminated mirror |
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| US3207358A (en) * | 1961-07-27 | 1965-09-21 | Gen Electric | Water storage tanks and methods of making the same |
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| IE60859B1 (en) * | 1987-07-10 | 1994-08-24 | Ici Plc | Articles that include glass sheeting |
-
1988
- 1988-07-05 IE IE204788A patent/IE60859B1/en not_active IP Right Cessation
- 1988-07-07 AU AU18835/88A patent/AU607782B2/en not_active Expired
- 1988-07-07 NZ NZ225331A patent/NZ225331A/en unknown
- 1988-07-08 CA CA000571528A patent/CA1332701C/en not_active Expired - Lifetime
- 1988-07-11 US US07/217,230 patent/US5089076A/en not_active Expired - Lifetime
-
1991
- 1991-08-28 US US07/750,310 patent/US5300174A/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| AU607782B2 (en) | 1991-03-14 |
| NZ225331A (en) | 1992-02-25 |
| IE60859B1 (en) | 1994-08-24 |
| US5089076A (en) | 1992-02-18 |
| US5300174A (en) | 1994-04-05 |
| IE882047L (en) | 1989-01-10 |
| AU1883588A (en) | 1989-01-12 |
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