Energy Efficient RF Lamination of Flat Glass and Ceramics for Solar and Armor Applications

Daytona Beach 2009 Presentation

Abstract

Advanced Ceramics and Composites
Daytona Beach, Florida
January 18-23, 2009

Authors: Shawn Allan, Morgana Fall, Dr. Holly Shulman
Presenter: Shawm Allan, Senior Materials Engineer

A 60 second method for producing laminated flat glass, hard plastics (polycarbonate and acrylic), and transparent ceramics was developed. The process used radio frequency (RF) energy to selectively heat and melt interlayers (vinyls, PVB and EVA, and thermoplastic polyurethane, TPU) via dielectric heating. Energy was focused in the interlayer, without directly heating the glass or surroundings. Uniaxial pressure was simultaneously applied. The method was successfully demonstrated for the production of laminated silicon solar panels, metallized (low-e) glass, and multilayer transparent armor-like structures, up to at least 1 ft². Demonstration results will be presented, along with strategies for scale-up of the workable product size. Various substrate and interlayer combinations were tested to determine the robustness of the process. Production energy savings from lamination with simultaneous pressure and RF energy resulted in approximately 90% energy savings over autoclave and vacuum oven processes. RF lamination was found to be a fast flexible method for rapid-prototyping and production of laminates.