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GLASS LAMINATION


·        Products

·       Processes

·        Applications

·        Advantages

·        New Products

 


Products

Liquid Glass Lamination Resins

Astrocure® 1000G (10G)

Astrocure® 1000G (10G) is a clear, low viscosity resin and is part of a three component mix system, designed for use in the following applications:

·        Safety – personal protection

·        Security – missile protection

·        Sound Deadening – protection against sound

·        Solar – protection from weathering conditions

·        Decorative – cosmetically appealing windows, etc.

Astrocure® 1500G

Astrocure® 1500G is a clear, low viscosity resin similar to Astrocure® 1000G (10G).  It is designed for fabricators, who operate in hot climates (international).  Characteristics that are different from the Astrocure® 1000G (10G) include:

·        Lower Viscosity

·        Higher elongation

·        Lower reactivity shrink

Applications include all of the above.

Astrocure® 2000G

Astrocure® 2000G is part of a three part system designed specifically for multiple glass structures (bullet resistant glass).  Windows made with Astrocure® 2000G will pass UL 792 test at all levels and at high, low, and room temperature conditions.  In addition to low shrinkage, this resin will cure in a thin film (air promoted).

Astrocure® 3000G

Astrocure® 3000G is a clear, low viscosity resin that will cure between two pieces of glass with ultra-violet radiation.  It is one component (no mixing).  Unlike the three component systems, shop temperatures do not affect initiation or cure of the resin.  Gel time, or the time at which the liquid resin turns from a liquid to a solid, does not occur until exposure to ultra-violet radiation (patent pending).

Applications of this product include all those stated with Astrocure® 1000G (10G).

Astrocure® 5000G

Low shrinkage and non-etching properties with polycarbonate and a variety of other plastic castings and films are the main advantages versus the other previously mentioned products.

Applications include lamination of patterned glass, slump glass and fabrication of bullet resistant laminates based on glass, polycarbonate, acrylic, polyester and PVC films and castings (patent protected).

The Astrocure® 5000G system is a three component mix.

 

Glass Additives

Astrocure® C-88

Resin activator for three component systems.

Astrocure® P-88

Glass adhesion promoter for three component systems.

Astrocure® P-97

Plastic adhesion promoter three component systems.

 

Dyes and Tints

These liquid Dyes and Tints are designed to be used in three component systems for imparting clear colors in glass laminates.  Levels vary from 1-3% by  resin weight.

·        AstroRed 10 – fire engine red
·        AstroRed 11 – purple red
·        AstroBlue 10 – turquoise blue
·        AstroBlue 11 – deep dark blue
·        Astroyellow 10 – canary yellow
·        AstroYellow 11 – mustard yellow
·        AstroOrange 10 – orange
·        AstroGreen 10 – kelly green
·        AstroGreen 11 -  hunter green

All dyes and tints are colorfast.

 

Pigments

These pastes are designed to be used with three component systems for imparting opaque color to glass laminates.  Levels vary from 1-3 % by resin weight.

·        AstroRed Opaque
·        AstroBlue Opaque
·        AstroYellow Opaque
·        AstroGreen Opaque
·        AstroWhite Opaque
·        AstroBlack Opaque
·        AstroBrown Opaque

 

Pearlescent Fillers

These solids, when added to a three component resin system, give a decorative reflective appearance.  Depending on levels, the effects can be translucent or opaque.

·        AstroGlimmer Gold
·        AstroGlimmer Red-Brown
·        AstroRed-Brown
·        AstroSatin Blue
·        AstroPearl
·        AstroSatin
·        AstroGlimmer Bronze
·        AstroGlimmer Green
·        AstroGlimmer Blue
·        AstroGlimmer Red

 

Etch-N_Seal

Etch-N-Seal are liquid resinous products that are designed to seal etched glass against finger prints, dirt, etc.

·        Etch-N-Seal 1 simply seals the etched glass with a minimum change in cosmetics.
·        Etch-N-Seal 10 seals etched glass and allows the use of the Zircon liquid lamination process for converting etched glass into impact glass without change in cosmetics.  A variety of colors can be added to Etch-N-Seal to highlight the etched surface.

 

Cleaners

·        Astroclean I – Industrial cleaner
·        Astroclean II – Industrial cleaner concentrate.

 

Mixing Equipment

·        Astromix 1000 – Low cost mixing system for three component resin systems
·        Astromix 2000 – High capacity mixing system

 

Starter Kit

·        5 gallons of Glass Lamination Resin
·        8 ounces of Adhesion Promoter
·        8 ounces of Activator
·        Large Pitcher
·        Small Pitcher
·        2 Graduated Dispensers
·        Mixing Spoon
·        1 roll 30 mils double sided ¼” tape (Norton)
·        1 roll 60 mils double sided ¼” tape (Norton)
·        1 roll 40 mils clear double sided tape (3M)
·        1 roll of 30 mils double sided 1/8” tape (Capital)
·        Baggies
·        Clear Tubing
·        2 Squeegees
·        Razor & Dispenser
·        Scissors
·        Syringe and 3 needles
·        Putty
·        Astroclean
·        Video/Packet
·        Spatula

 


Processes

I. Double Glass – Shown on video upon request.

Two pieces of glass are held together with double-sided tape as a diking system.  Activated resin is introduced, at an angle between the glass.  Air is removed by placing the composite in a horizontal position.  After sealing all sides, the laminate is allowed to cure overnight (10-12 hours).  The finished product is ready for shipment.

II. Single Glass – High Production.

A continuous line is set up to make a piece of laminated glass every 1 ½ - 2 minutes.

Stage I  - Double sided tape is applied to all four sides of a single piece of cleaned and dried glass and the protective coating is removed.

Stage II – Activated resin is introduced at the center of the glass

Stage III – A second piece of glass is placed in an overlap position to the first and sealed on all four sides, trapping the resin and air between the two pieces of glass.

Stage IV – Since the tape is porous, air is removed with a vacuum chamber.

Stage V – After inspection for any air bubbles, the laminated piece of glass is placed on a rack for room temperature cure.  The product can be shipped the next day.

III. Multiple Glass – Security

Multiple layers of glass and/or polycarbonate can be made quickly and easily by applying double sided tape to 3 sides of each piece of glass and connecting the various pieces in an overlap position.  The three sides are re-enforced with polysulfide seal to prevent leakage.  With the structure on its edge, activated resin is introduced through the fourth side.  Resin goes to the bottom, pushing the air to the top.

After room temperature cure, the fourth side is sealed with polysulfide polymer and is ready for shipment.

 


Applications

Safety

·        High Rise Buildings
·        Entrance Doors and Sliding Glass Doors
·        Entrance Building Window
·        Skylight Windows

Security

·        Bullet Resistant Windows
·        Department Store Windows
·        Hurricane Resistant Windows
·        Blast Resistant Windows
·        Automotive Windows
·        Laminated Mirrors
·        Shower Doors

Solar

·        Insulated Windows
·        Solar Glass Panels

Sound Deadening

·        Hotel Windows
·        Airports
·        Plant Windows
·        Automotive Windows

Decorative

·        Crackle (Ice) Glass – Furniture
·        Colored Glass – Clear and Opaque
·        Patterned Glass
·        Etched Glass
·        Slump Glass
·        Other

 


Advantages

Capital Expenditures

Using the double glass process, no autoclav, ultra-violet curing ovens or heat ovens are required.  Capital expenditures are at a minimum.  Although a glass washer is recommended, the float glass can be cleaned by hand.  Only equipment to cut glass to size and a tilt table are required.  Ten to fifteen pieces of insulated glass per day can be made using this method.  This method is designed for specialty glass production.

If major quantities of laminated glass re to be manufactured (2-5 million sq. ft./yr.), the Single Glass Method is recommended.  This process is highly automated and requires special equipment.  Curing racks, warehouse space and a one day inventory is required for this process.  Estimated cost is ½ million dollars/per line.

For Security Glass Application, the multiple glass procedure is recommended.  See Multiple GlassProcess.

 

Energy Dependence

No heat, light or pressure is required with the Cold Cure Liquid Glass Lamination Process.  Only the ability to mix and place said mix between glass is necessary.  The cold cure aspect of this process makes it easy to laminate mirrors, film, plastic castings, wood, metal parts, and marble.

 

Labor Dependence

With the Double Glass Method, a single worker can produce ten to fifteen pieces of laminated glass per day.  This assumes that glass cutting equipment, glass cleaning equipment, a tilt table, and adequate mixing equipment is available.  If a single worker were making exclusively, 8 ft. by 4 ft. pieces of laminated glass, the monthly production would be 6,400 to 9,600 sq. ft. (2.7-4.0 drums of liquid resin).

            1 man hour (assuming a 6 hour day)

                        =  (6,400 sq. ft.) 320 sq. ft./day = 53.3 sq. ft./hr. (1.67 pieces)

                        or (9,600 sq. ft.) 480 sq. ft./day =80.0 sq. ft./hr (2.5 pieces)

With the Single Glass Method (High Production), three to four laborers would be needed to man the line.  A piece of glass is made every 1 ½-2 minutes by this method.  One line and one shift could produce 1.38-1.80 million ft./year with a 6 hour day.

            1 man hour (assuming a 6 hr. day)

                        = 1,280 sq. ft./day/4 workers = 320 sq. ft./ man hour

 

Response Time

Specialty and difficult to make glass laminates can easily be fabricated and installed the following day.  Response time is a major advantage of the Zircon Cold Cure Liquid Glass Lamination Process.

 

Installation Yields and Inventory

Normally, a local glass shop will purchase a small billet (1,250 sq. ft.) or a large billet (2,400 sq. ft.) from a distributor.  This material represents a sizable inventory.  When orders are places, the single piece of laminated glass must be cut to size (not an easy procedure).  A certain loss is incurred, depending on the size to be cut.  With the Zircon liquid system, a laminated piece of glass can be made to size and can be installed the next day.  If necessary, the laminated glass can be easily cut.

In addition to carrying a heavy glass inventory, one size fits all. When purchasing a billet of glass it is either 1/8” x 1/8”, ¼” x ¼”, or ½” x ½” thick.  With the Zircon cold cure process, a variety of glass laminate thicknesses can easily be done.

 

Versatility

With the Zircon Cold Cure Liquid Glass Lamination Process, the glass fabrication uses a fluid liquid resin.  Liquids seek their own level, enabling the manufacture of bent glass, glass structures that are irregular in surface (tempered glass), and decorative glass that may vary in thickness.  Tints, fillers and pigments can be incorporated into the resin mix.  Lamination is not restricted to glass.  Films, plastic sheets, wood, and metal substrates can be laminated to float glass.  The system is so versatile that applicators are only restricted by lack of imagination.



NEW PRODUCTS AND DEVELOPMENTAL  PRODUCTS

 

NEW PRODUCTS:

Astrocure® 1010G

This product is similar to Astrocure® 1000G (10G), except no adhesion promoter needs to be added.  Only the activator is added at 1% of  resin weight.  Dispensing equipment for said product is less expensive and more reliable.

Pricing upon request.

DEVELOPMENTAL PRODUCTS:

Dade County Approved Glass Laminate

The laminate passes impact testing at ¼” total thickness and is completely clear (no haze).  The process is a cold cure liquid process that is capable of producing 10,000 sq. ft. in a single day’s production.

Fire Rated Cold Cure Liquid Lamination System

Testing is in progress on a fire rated glass lamination system.

Zircon Corporation
322 Moore Lane
Collierville, TN 38017
(800) 343-0964
(901) 850-0561
fax (901) 850-0563
info@zirconcorp.com

© 2003 Zircon Corp.