JP2024516143A - Novel lamination process for producing laminated vacuum insulating glazing assemblies. - Google Patents

Abstract

A manufacturing method for making a laminated vacuum insulation glazing assembly (1) having at least one separately manufactured vacuum insulation glazing (2), at least one intermediate unit polymer (3), and at least one functional unit (4) pass ISO 12543-4:2011 includes at least the steps of 1) laminating (2), (3), and (4) to produce a preassembly, where (4) is treated at a treatment pressure of 5.5 to 15 bar, 2) inserting the preassembly into a vacuum ring or bag, 3) treating the preassembly by at least a. evacuating the vacuum ring or bag to a vacuum of minus 0.1 to minus 1 bar, b. heating the preassembly to 50 to 200°C, and c. pressurizing the preassembly under an overpressure of 4.5 bar or less to produce (1), and 4) releasing the evacuation 3)a), heating 3)b), and overpressure 3)c).
[Selected Figure] Figure 1

Description

The present invention relates to a novel method for manufacturing a laminated vacuum insulated glazing assembly that provides additional performance such as acoustics, safety, security, fire protection, and/or decoration.

Vacuum insulated glazing meets the market need for relatively high thermal insulation. They usually consist of at least two glass panes separated by an internal space where discrete spacers are placed so that a vacuum is created and prevents direct contact between the glass panes at atmospheric pressure. In addition to thermal insulation performance, the glass market is seeking to add further benefits to vacuum insulated glazing such as safety, security, acoustics, fire protection, decoration, etc.

Such additional benefits are typically provided to vacuum insulated glazing by lamination techniques. Nearly all lamination techniques require a pressurized autoclave finishing process at pressures above 10 atmospheres and temperatures up to 150°C to produce laminated glass of acceptable quality. In practice, during lamination, the temperature is typically increased up to 150°C to soften the interlayer and help it conform to the surface of the glass substrates and flow into areas where the substrate spacing may be uneven. Once the interlayer conforms, the mobile polymer chains of the interlayer create a bond with the glass. The elevated temperature also accelerates the diffusion of residual air and/or moisture pockets from the glass/interlayer interface into the interlayer. It is believed that pressure plays two important roles in the manufacture of glass laminates. First, pressure promotes the flow of the interlayer. Second, pressure suppresses the formation of air bubbles that would be created by the combined vapor pressure of water and air trapped in the system. The water and air trapped in the pre-press (i.e., the layered assembly of unbonded glass and interlayer) have a tendency to expand as bubbles when the pre-press assembly is heated at atmospheric pressure to a finishing temperature of above about 100° C. To suppress bubble formation, heat accompanied by overwhelming pressure is usually applied to the assembly in an autoclave vessel to counter the expansion forces generated when the air and water trapped in the pre-press are heated. And finally, time plays an important role in lamination. While temperature and pressure can accelerate lamination, a certain critical time must always elapse to produce good quality laminated glass.

However, due to the high pressure and/or high temperature requirements, such conventional lamination methods cannot be used for vacuum insulated glazing. In particular, the pressurized processing steps are not compatible with the essential properties of vacuum insulated glazing, and the discrete spacers placed between the two glass panes of the vacuum insulated glazing cannot withstand the required pressure, and/or microscopic cracks may appear on the glass panes around these discrete spacers, significantly degrading the mechanical strength of the vacuum insulated glazing and its thermal performance.

Therefore, lamination at atmospheric pressure or under very low pressure is used to laminate additional glass sheets to vacuum insulating glazing. For example, WO2020203550 discloses a method for laminating a transparent plate to vacuum insulating glazing via an intermediate film. The vacuum insulating glazing comprises a first glass panel, a second glass panel, a vacuum space disposed between the first and second glass panels, and a number of spacers made of resin. The process pressure for laminating the vacuum insulating glazing and the transparent plate together is less than the compressive strength of the number of spacers.

However, such low pressure requirements significantly reduce the flexibility of options for additional benefits that can be added to the vacuum insulating glazing. Most of the additional benefits provided by the functional units actually require high temperatures and/or pressures that are processed directly on the vacuum insulating glazing due to the mechanical resistance of the vacuum insulating glazing.

Therefore, those skilled in the art are searching for new lamination methods to provide additional superior benefits to the vacuum insulated glazing, which allow the benefits of the vacuum insulated glazing to be combined with the performance of the functional unit without degrading the mechanical and functional properties of the vacuum insulated glazing. Thus, to resist the lamination method, the vacuum insulated unit is designed to have the following properties, so that further benefits are added to the vacuum insulated unit via the functional unit:
(1) the intrinsic load (L _int ), which is all the stresses inherent to the vacuum insulated glazing design itself, such as the mechanical resistance of the discrete spacers, the thickness of the glass panes, the atmospheric pressure, etc.;
(2) the lamination load (L _lam ), which is the total stress introduced by the lamination process on the vacuum insulated glazing; and
(3) Use Load (L _use ), which is all the stresses generated by the conditions of use of the vacuum insulated glazing, such as temperature difference between the inside and outside environment, wind, etc.
The load must be designed to withstand the load.

It is therefore an object of the present invention to provide a novel manufacturing method that allows the performance of a functional unit to be added to the benefits of the vacuum insulation glazing without compromising the mechanical and functional properties of both the vacuum insulation glazing and the functional unit, while keeping the manufacturing method cost-effective and simple.

The present invention relates to a method for manufacturing a laminated vacuum insulation glazing assembly (1) that meets the high temperature test standard ISO 12543-4:2011. The method comprises at least
1) laminating a vacuum insulation glazing (2), an intermediate unit polymer (3) and a functional unit (4) thereby producing a preassembly, wherein said functional unit is processed at a processing pressure (PP) of 5.5 bar to 15.0 bar (5.5 bar > PP > 15.0 bar), preferably 7.5 bar to 14.0 bar (7.5 bar > PP > 14.0 bar), more preferably 10.0 bar to 14.0 bar (10.0 bar > PP > 14.0 bar),
2) inserting the pre-assembly into a vacuum ring or vacuum bag, preferably into a vacuum bag;
3) At a minimum,
a. evacuating the inside of the vacuum ring or vacuum bag to a vacuum of minus 0.1 bar to minus 1 bar, preferably minus 0.5 bar to minus 1 bar;
b. heating the preassembly to a temperature in the range of 50° C. to 200° C., preferably 75° C. to 175° C., more preferably 90° C. to 150° C.;
c) pressurizing the preassembly under an overpressure (OP) of 4.5 bar or less (OP≦4.5 bar);
processing the pre-assembly to produce a laminated VIG assembly by
4) releasing the exhaust 3) a), the heating 3) b), and the overpressure 3) c);
including.

In a preferred embodiment, the functional unit includes at least two sheets, preferably at least one of the sheets is a glass sheet, and more preferably at least two of the sheets are glass sheets.

In a preferred embodiment, the overpressure in substep 3)c) is less than or equal to 4.0 bar (OP≦4.0 bar), preferably less than or equal to 3.0 bar (OP≦3.0 bar), preferably less than or equal to 2.0 bar (OP≦2.0 bar), preferably less than or equal to 1.5 bar (OP≦1.5 bar), preferably less than or equal to 1.0 bar (OP≦1.0 bar), preferably less than or equal to 0.5 bar (OP≦0.5 bar), and more preferably equal to 0 bar (OP=0 bar).

In a preferred embodiment, the substeps of the process step 3) are realized in the following order: evacuation substep 3)a), heating substep 3)b), and pressurization substep 3)c), preferably heating substep 3)b) and pressurization substep 3)c) are started simultaneously.

In a preferred embodiment, evacuation substep 3)a) of process step 3) is carried out at ambient temperature for a period of 5 minutes to 40 minutes, preferably 10 minutes to 30 minutes, more preferably 20 minutes to 30 minutes.

In a preferred embodiment, the releasing step 4) is preferably achieved by first releasing the heat and then releasing the exhaust, preferably releasing the exhaust and pressure together, when the temperature of the VIG laminate assembly reaches 50°C to 60°C, more preferably ambient temperature.

In a preferred embodiment, the heat release step in step (4) is preferably carried out at a temperature of 130°C to 30°C at a rate of 1 to 10°C/min, preferably 2 to 9°C/min, preferably 3 to 8°C/min, preferably 4 to 7°C/min, more preferably 5 to 6°C/min. This is particularly suitable when the intermediate unit polymer is ethylene vinyl acetate and/or an ionomer, preferably ethylene vinyl acetate.

In a preferred embodiment, the laminated vacuum insulated glazing assembly satisfies the loading formula L _lam ≦[L _int (SF−1)]+[L _use ×SF], where:
- L _lam is the lamination load, which is the total stress caused by the lamination process on the vacuum insulated glazing;
- L _int is the intrinsic load, which is all the stresses inherent in the vacuum insulated glazing design;
-SF is the security factor,
-L _use is the service load, which is all the stresses generated by the use conditions of the vacuum insulating glazing.

In a preferred embodiment, the intermediate unit polymer is selected from the group consisting of ethylene vinyl acetate (EVA), cyclopolyolefin polymer (COP), autoclave-free polyvinyl butyral (autoclave-free PVB), polyurethane (PU), and/or ionomer, preferably selected from ethylene vinyl acetate (EVA) and/or autoclave-free polyvinyl butyral (autoclave-free PVB).

In a preferred embodiment in which the intermediate unit polymer is autoclave-free polyvinyl butyral, the temperature of heating substep b) of process step 3) is in the range of 90°C to 150°C, preferably 115°C to 150°C, preferably 135°C to 145°C, more preferably 140°C, for a period in the range of 20 to 180 minutes, more preferably 60 minutes.

In a preferred embodiment, where the intermediate unit is polyurethane, the temperature of heating substep b) of process step 3) is in the range of 90°C to 150°C, preferably 110°C to 120°C, for a period in the range of 20 to 180 minutes, more preferably 60 minutes. In a preferred embodiment, pressurizing substep 3)c) is carried out under an overpressure (OP) of 2.0 bar to 4.5 bar (2.0 bar < OP < 4.5 bar), preferably 2.0 bar to 4.0 bar (2.0 bar < OP < 4.0 bar), more preferably 3.0 bar.

In a preferred embodiment, where the intermediate unit polymer is ethylene vinyl acetate and/or a cyclopolyolefin polymer, preferably ethylene vinyl acetate, the temperature of heating substep b) of process step 3) is in the range of 90°C to 150°C, preferably 110°C to 145°C.

In a preferred embodiment in which the intermediate unit polymer is ethylene vinyl acetate, processing step (3) comprises, prior to substep b), a further substep b*) of heating to an intermediate temperature in the range of 75°C to 95°C for a period of preferably 10 to 60 minutes, more preferably 15 to 40 minutes.

In a preferred embodiment in which the intermediate unit polymer is ethylene vinyl acetate, the sub-steps of process step (3) include:
a) evacuation at room temperature for a period of 5 minutes to 40 minutes, preferably 10 minutes to 30 minutes, more preferably 20 minutes to 30 minutes;
b*) heating to an intermediate temperature in the range of 75°C to 95°C, preferably for a period of 10 to 60 minutes, more preferably 15 to 40 minutes;
b) heating to a temperature in the range of 110° C. to 145° C., preferably 130° C. to 140° C., for a period of 45 min to 300 min;
c) pressurizing under an overpressure (OP) of 2.0 bar or less (OP≦2.0 bar), preferably 1.5 bar or less (OP≦1.5 bar), preferably 1.0 bar or less (OP≦1.0 bar), preferably 0.5 bar or less (OP≦0.5 bar), more preferably under no overpressure of 0 bar (OP=0 bar);
This is achieved in the following processing order:
In this case, preferably sub-steps b) and c) are carried out simultaneously.

In a preferred embodiment in which the intermediate unit polymer is an ionomer, the heating substep b) of process step (3) is carried out at a temperature of 90°C to 150°C, preferably 130°C to 135°C, for a period of preferably 45 minutes to 75 minutes, preferably 60 minutes.

In one preferred embodiment, the functional unit includes at least two glass sheets laminated with a polyvinyl butyral polymer interlayer.

In one preferred embodiment, the functional unit includes at least one structural plastic sheet, preferably a polycarbonate sheet, and at least one glass sheet laminated with at least one polyvinyl butyral polymer interlayer and at least one polyurethane polymer interlayer.

In a preferred embodiment, the polyvinyl butyral polymer interlayer is an acoustic polyvinyl butyral polymer interlayer and/or the multiple sheets each have a different thickness.

In a preferred embodiment, the functional unit comprises at least two glass sheets separated by an expansion material, preferably an alkali metal hydroxide silicate. In a preferred embodiment, the functional unit further comprises a peripheral spacer, thereby creating a space between the two glass sheets for the expansion material, in which case the heating substep b) of the process step 3) is realized at a temperature of 120°C or less, preferably 110°C or less, preferably 100°C or less, more preferably 90°C or less.

In a preferred embodiment, at least one of the first and second glass panes of the vacuum insulated glazing and/or at least one of the sheets of the functional unit is heat strengthened glass, heat toughened safety glass, or chemically strengthened glass.

In a preferred embodiment, the discrete spacers of the vacuum insulating glazing are made of a metal material, quartz glass, a ceramic material, and/or a resin, preferably a resin, more preferably a polyimide resin.

FIG. 2 shows a cross-sectional view of a laminate vacuum insulation assembly according to one embodiment of the present invention, where a vacuum insulation glazing is laminated with an intermediate unit polymer to a functional unit having two sheets.

The present invention relates to a method for manufacturing a "laminated vacuum insulated glazing assembly", hereinafter referred to as a "laminated VIG assembly", having at least two separate units: a vacuum insulated glazing, hereinafter referred to as a "VIG", and a functional unit. The VIG and the functional unit are manufactured separately as a laminate preassembly before being laminated together with an intermediate unit polymer to form the laminated VIG assembly in the manufacturing method of the present invention.

Those skilled in the art will appreciate that the terms "a," "an," or "the" as used herein mean at least "one" and should not be limited to "only one," unless expressly indicated otherwise.

Method The object of the present invention is to produce a laminated vacuum insulated glazing assembly that combines the excellent insulation, thickness and weight properties of vacuum insulated glazing with several other functions such as safety, security, acoustic, fire protection, decorative etc. properties provided by the functional unit without degrading the functional or mechanical properties of the vacuum insulated glazing unit or functional unit.

A further object of the present invention is to obtain such superior performance while avoiding over-designing the VIGs, functional units, and/or the entire laminate VIG assembly, which can result in unnecessary complexity, expense, and can degrade the thermal performance, optical clarity, weight, thickness, processability, and shipping of the laminate VIG assembly.

Conventional lamination methods, in which high temperature and/or high pressure conditions are applied, have been found in some instances to degrade the mechanical properties and/or thermal performance of the vacuum insulated glazing. Surprisingly, it has been found that the method of the present invention, in which the vacuum insulated glazing and the functional unit are manufactured separately and then laminated together under mild overpressure conditions, allows the integrity of the vacuum insulated glazing to be maintained and provides the laminated VIG assembly with superior functional properties that cannot otherwise be provided to the vacuum insulated glazing by the method of the present invention.

Thus, the present invention is directed to the manner in which a laminated VIG assembly must be designed and engineered to support a variety of loads, i.e., intrinsic loads, service loads, and lamination loads. The laminated VIG assembly and its method of manufacture include:
(1) The laminate VIG assembly is designed to withstand an intrinsic load (L _int ) and a service load (L _use ), both of which are supplemented by a specified design security factor, such that: Design load >= (L _int +L _use ) x SF; and
(2) The laminate VIG assembly similarly resists the combined intrinsic and lamination loads such that Design Load >= L _int + L _lam .
It has been found that the lamination load needs to be designed such that L _lam ≦[L _int (SF−1)]+[L _use ×SF].

The skilled person is offered different routes to resist the loads (L _lam ) brought about by the lamination process according to the above formula and thus to avoid damage to the functional or mechanical properties of the vacuum insulation glazing.
(1) One potential route would be to increase the service loads, however, if the laminate VIG assembly were designed to withstand relatively large service loads, it would be unnecessarily over-engineered.
(2) Another potential route would be to increase the thickness of the glass panes of the VIG, thereby increasing the security factor. Again, this would result in the laminate VIG assembly being unnecessarily over-engineered, which would degrade the advantageous properties of the VIG's thickness and light weight.
(3) Another engineering approach would be to increase the number of discrete spacers to allow for reduced intrinsic and lam loading, however, such a route would significantly reduce the thermal performance of the VIG and would be unnecessarily over-engineered.
Such over-engineering should be avoided because it introduces unnecessary complexity, expense, and can degrade the thermal performance, optical clarity, weight, thickness, processability, and shipping of the laminated VIG assembly.
(4) Finally, therefore, the last potential route is to design a manufacturing method with reduced lamination loads, i.e. at relatively low pressures and/or temperatures, although such a manufacturing method would not allow the utilization of all functional units that actually require the creation of high pressure and/or high temperature conditions.

As mentioned above, over-engineering of vacuum insulation glazing is not an economically viable option. Lamination at relatively low pressure would actually eliminate functional units that require high pressure and/or high temperature conditions. Such functional units are usually processed at processing pressures (PP) of 5.5 bar to 15.0 bar. Therefore, there remains a need to develop a manufacturing method that combines and maintains the excellent thermal properties of the VIG as well as the functional properties of the added functional units. It has been found that the novel manufacturing method of the present invention, in which the functional units and the VIG are manufactured in separate steps and then laminated together under moderate overpressure, offers maximum flexibility in additional technical performance to the VIG while avoiding over-engineering and/or reducing the thermal performance of the VIG components. In fact, the present invention allows the addition of high pressure processed functional units to the VIG via a lamination method at low pressure.

Furthermore, the novel manufacturing method for laminated VIG assemblies can be performed in a single step in a single industrial machine, and is therefore easy, simple, efficient, and cost-effective.

A laminated VIG assembly can have at least one VIG and at least one functional unit. Typically, a laminated VIG assembly has one VIG and one functional unit. However, in some embodiments, a laminated VIG assembly can have multiple functional units added to the same side of the VIG or to both sides of the VIG. Also, embodiments in which a laminated VIG assembly has multiple VIGs with one or more functional units could be envisioned. All combinations of one or more VIGs and one or more functional units are encompassed herein.

In a preferred embodiment of the present invention, the laminated VIG assembly has one VIG and one functional unit.

The laminate assembly, i.e., the VIG and functional units, as well as the panes of the VIG and the sheets of the functional units, extend along a plane P defined by a longitudinal axis X and a vertical axis Z. Each of these elements has a thickness measured in a direction perpendicular to the plane P and has a surface extending along the plane P.

The present invention relates to a method for producing a laminated VIG assembly (1) having a VIG (2) and a functional unit (4), where the VIG and the functional unit are produced in separate steps. Suitable intermediate unit polymers to be used in the method of the present invention to laminate the functional unit and the VIG to form the laminated VIG assembly of the present invention are polymers that have the ability to provide adequate mechanical adhesion upon lamination at moderate overpressure.

During lamination, the intermediate unit polymer can be deposited on the surface of the VIG and/or functional unit and disposed between the vacuum insulating glazing and the functional unit, thereby creating a preassembly.

Proper mechanical adhesion through lamination means that the resulting laminated VIG assembly will pass the high temperature test (also called the bake test) of the durability section of the NBN EN ISO 12543 standard dated October 2011, "Glass in building - Laminated glass and laminated safety glass - Part 4: Test methods for durability (ISO12543-4:2011)".

Overpressure means an additional pressure above atmospheric pressure. Mild overpressure means an overpressure of less than or equal to 4.5 bar (OP≦4.5 bar), preferably less than or equal to 4.0 bar (OP≦4.0 bar), preferably less than or equal to 3.0 bar (OP≦3.0 bar), preferably less than or equal to 2.0 bar (OP≦2.0 bar), preferably less than or equal to 1.5 bar (OP≦1.5 bar), preferably less than or equal to 1 bar (OP≦1 bar), preferably less than or equal to 0.5 bar (OP≦0.5 bar), more preferably equal to 0 bar (OP=0 bar).

Therefore, suitable intermediate unit polymers to be used in the method of the present invention are those that provide adequate mechanical adhesion between the functional unit and the VIG such that the resulting laminated VIG assembly passes the high temperature test ISO 12543-4:2011 at an overpressure of 4.5 bar or less (OP≦4.5 bar), preferably 4.0 bar or less (OP≦4.0 bar), preferably 3.0 bar or less (OP≦3.0 bar), preferably 2.0 bar or less (OP≦2.0 bar), preferably 1.5 bar or less (OP≦1.5 bar), preferably 1 bar or less (OP≦1 bar), preferably 0.5 bar or less (OP≦0.5 bar), and more preferably equal to 0 bar (OP=0 bar).

In a preferred embodiment, suitable intermediate unit polymers to be used in the process of the present invention are selected from the group consisting of ethylene vinyl acetate (EVA), cycloolefin polymer (COP), autoclave-free polyvinyl butyral (hereinafter referred to as autoclave-free PVB), polyurethane (PU), ionomers such as SentryGlas™, and combinations thereof.

The present invention relates to a method for manufacturing a laminated vacuum insulation glazing assembly (1) that meets the high temperature test standard ISO 12543-4:2011, which comprises at least:
1) laminating a vacuum insulation glazing (2), an intermediate unit polymer (3) and a functional unit (4) thereby producing a preassembly, wherein said functional unit is processed at a processing pressure (PP) of 5.5 bar to 15.0 bar (5.5 bar > PP > 15.0 bar), preferably 7.5 bar to 14.0 bar (7.5 bar > PP > 14.0 bar), more preferably 10.0 bar to 14.0 bar (10.0 bar > PP > 14.0 bar),
2) inserting the pre-assembly into a vacuum ring or vacuum bag, preferably into a vacuum bag;
3) At a minimum,
a. evacuating the inside of the vacuum ring or vacuum bag to a vacuum of minus 0.1 bar to minus 1 bar, preferably minus 0.5 bar to minus 1 bar;
b. heating the preassembly to a temperature in the range of 50° C. to 200° C., preferably 75° C. to 175° C., more preferably 90° C. to 150° C.;
c) pressurizing the preassembly under an overpressure (OP) of 4.5 bar or less (OP≦4.5 bar);
processing the pre-assembly to produce a laminated VIG assembly by
4) releasing the exhaust 3) a), the heating 3) b), and the overpressure 3) c);
including.

The functional units herein are processed at high pressures, i.e., at processing pressures (PP) of 5.5 bar to 15.0 bar (5.5 bar > PP > 15.0 bar), preferably 7.5 bar to 14.0 bar (7.5 bar > PP > 14.0 bar), more preferably 10.0 bar to 14.0 bar (10.0 bar > PP > 14.0 bar), to provide superior benefits. The functional units preferably have at least two sheets, preferably at least one of the sheets is a glass sheet, more preferably at least two of the sheets are glass sheets.

In a preferred embodiment of the method of the present invention, the overpressure in substep b) of process step 3) is less than or equal to 4.0 bar (OP≦4.0 bar), preferably less than or equal to 3.0 bar (OP≦3.0 bar), preferably less than or equal to 2.0 bar (OP≦2.0 bar), preferably less than or equal to 1.5 bar (OP≦1.5 bar), preferably less than or equal to 1.0 bar (OP≦1.0 bar), preferably less than or equal to 0.5 bar (OP≦0.5 bar), and more preferably equal to 0 bar (OP=0 bar).

The skilled artisan will appreciate that when the method of the present invention is carried out at an overpressure equal to 0 bar, this is carried out without further overpressure, i.e. at atmospheric pressure, and no release of overpressure is required.

Those skilled in the art will appreciate that any other vacuum device, such as a vacuum chamber, may be used instead of a vacuum bag or vacuum ring to achieve the same purpose of exposing the pre-assembly to a vacuum, especially in the method of the present invention where no overpressure is used (OP=0 bar). When a vacuum bag is used, it is preferable to surround the pre-assembly with a breather frame to increase the degassing phenomenon.

Preferably, the method of the present invention will not have a system of pressure rollers or calenders (single or double) so that overpressure is not achieved through calender rolls, nip rollers, or any other rollers to avoid degradation of mechanical resistance and to maintain the integrity of the laminated VIG assembly.

With the sub-step of process step 3) being evacuation a), heating b) and pressurization c) can be performed in any order. However, in a preferred embodiment of the present invention, the sub-steps of process step 3) are realized in the process order of evacuation sub-step 3)a), heating sub-step 3)b), and pressurization sub-step 3)c), and preferably heating sub-step 3)b) and pressurization sub-step 3)c) are started simultaneously. Such a preferred embodiment is found to improve the evacuation of air at low temperatures. The increased pressure will assist the evacuation and the heating will allow the edge seal of the assembly to prevent air from returning to the structure.

In a preferred embodiment of the present invention, evacuation substep a) of process step 3) is initiated at ambient temperature for 5 to 40 minutes, preferably 10 to 30 minutes, more preferably 20 to 30 minutes, before heating substep 3)b) is initiated. Such a preferred embodiment has been found to allow smooth evacuation of air trapped between the intermediate unit polymer and the VIG and/or functional units.

In a further preferred embodiment of the present invention, the releasing step 4) of the method of the present invention is realized by first releasing the heat and then releasing the evacuation, preferably releasing the evacuation and the pressure together. This is preferably performed when the temperature of the VIG laminate assembly reaches 50°C to 60°C, more preferably when it reaches ambient temperature. In fact, cooling under vacuum is advantageous because it reduces the formation of air pockets and haze in the laminate VIG assembly.

In a further preferred embodiment of the present invention, the heat release sub-step of step (4) of the method is carried out to achieve a decrease of 1-10°C/min, preferably 2-9°C/min, preferably 3-8°C/min, preferably 4-7°C/min, more preferably 5-6°C/min, especially in the temperature range of 130°C to 30°C. Indeed, this is particularly preferred in embodiments where the intermediate unit polymers used to form the laminated VIG units are EVA, COP, and/or ionomers. The cooling step of the method of the present invention will preferably be carried out at a high speed to avoid the appearance of haze. Convection cooling or conduction cooling using a flow of cooling gas, such as by a fan with or without a heat exchanger, can be used.

The method of the invention is usually carried out in a clean room to avoid contamination as well as to respect specific temperatures and low humidity levels when required.

In a preferred embodiment, suitable intermediate unit polymers to be used in the process of the present invention are selected from the group consisting of ethylene vinyl acetate (EVA), cycloolefin polymer (COP), autoclave-free polyvinyl butyral (hereinafter referred to as autoclave-free PVB), polyurethane (PU), and/or ionomers such as SentryGlas™.

Methods involving autoclave-free PVB In the method of the invention, where the intermediate unit polymer used to form the laminated VIG assembly is autoclave-free PVB, an initial step of preconditioning the autoclave-free PVB to specific relative humidity and temperature conditions is preferably added. This is preferred in order to obtain good quality of the laminated VIG assembly, especially after the lamination cycle, and in particular to avoid bubble formation at the edges of the laminated VIG assembly. Such autoclave-free PVB usually requires specific humidity conditions for storage and processing, e.g. exhibiting a moisture content of less than 20%, preferably less than 15%, more preferably less than 10%, and a temperature of 15°C to 30°C, preferably 18°C to 25°C. Thus, in this embodiment where the intermediate unit polymer is autoclave-free PVB, the method of the invention preferably has an initial step of preconditioning the autoclave-free PVB at a relative humidity of 10% or more and at 25°C for at least 10 hours, preferably at least 12 hours.

In this embodiment, the heating substep b) of process step 3) of the method of the present invention preferably involves heating the pre-assembly at a temperature between 90°C and 150°C, preferably between 115°C and 150°C, preferably between 135°C and 145°C, more preferably at 140°C. This is preferably achieved over a period in the range of 20 to 180 minutes, preferably for 60 minutes.

Thus, in one preferred embodiment of the present invention, substeps a) and b) of process step (3) of the method of the present invention comprise:
a. evacuating to a vacuum of minus 0.1 bar to minus 1 bar, preferably minus 0.5 bar to minus 1 bar, in a vacuum ring or vacuum bag at room temperature for a period ranging from 5 minutes to 40 minutes, preferably from 10 minutes to 30 minutes, more preferably from 20 minutes to 30 minutes;
b. heating at a temperature of 90°C to 150°C, preferably 115°C to 150°C, preferably 135°C to 145°C, more preferably 140°C, for a period preferably in the range of 20 to 180 minutes, preferably for 60 minutes;
This is realized in the following processing order.

In a further preferred embodiment, the pressurization substep 3)c) is carried out under an overpressure (OP) of 2.0 bar or less (OP≦2.0 bar), preferably 1.5 bar or less (OP≦1.5 bar), preferably 1.0 bar or less (OP≦1.0 bar), preferably 0.5 bar or less (OP≦0.5 bar), more preferably under no overpressure of 0 bar (OP=0 bar).

Preferably, the heating substep b) and the pressure applying substep c) of process step 3) are initiated simultaneously.

All of these preferred features are combined in a further preferred method of the present invention in which the intermediate unit polymer is autoclave-free PVB.

In the process of the present invention where the intermediate unit polymer used to form the laminate VIG assembly is polyurethane (PU), the heating step b) of processing step 3) of the process of the present invention preferably involves heating the pre-assembly at a temperature of from 90° C. to 150° C., preferably from 110° C. to 120° C. This is preferably achieved for a period in the range of from 20 to 180 minutes, more preferably for 60 minutes.

Thus, in such a preferred embodiment of the present invention, sub-steps a) and b) of process step (3) of the method of the present invention comprise:
a. evacuating to a vacuum of minus 0.1 bar to minus 1 bar, preferably minus 0.5 bar to minus 1 bar, in a vacuum ring or vacuum bag at room temperature for a period ranging from 5 minutes to 40 minutes, preferably from 10 minutes to 30 minutes, more preferably from 20 minutes to 30 minutes;
b. heating at a temperature of 90°C to 150°C, preferably 110°C to 120°C, for a period preferably in the range of 20 to 180 minutes, preferably 60 minutes;
This is realized in the processing order.

In a further preferred embodiment, the pressurization substep 3)c) is carried out under an overpressure (OP) of 2.0 bar to 4.5 bar (2.0 bar <= OP <= 4.5 bar), preferably 2.0 bar to 4.0 bar (2.0 bar <= OP <= 4.0 bar), more preferably about 3.0 bar.

Preferably, the heating substep b) and the pressure applying substep c) of process step 3) are initiated simultaneously.

All of these preferred features are combined in a further preferred method of the present invention in which the intermediate unit polymer is polyurethane (PU).

Process with EVA and/or COP In the process of the present invention, the preferred intermediate unit polymer for forming the laminate VIG is selected from EVA and/or COP, more preferably EVA.

In the process of the present invention, where the intermediate unit polymers used to form the laminated VIG assembly are EVA and/or COP, particular attention must be paid to the quality of the vacuum and temperature profile. The temperature ranges and their durations are easily adapted by those skilled in the art depending on the parameters of the laminated VIG assembly such as total thickness, thermal inertia of the glass, volume of glass, etc.

Thus, in a preferred embodiment where the intermediate unit polymers used to form the laminated VIG unit are EVA and/or COP, the heating substep b) of process step 3) of the method of the present invention will preferably comprise an initial step of pre-bonding the EVA intermediate unit polymer by heating at a temperature of 75°C to 95°C for a period of preferably 10 to 60 minutes, more preferably 15 to 40 minutes, to provide for the elimination of trapped air between the EVA or COP intermediate unit polymer and the glass surface of the VIG and functional units due to the obtained optimal viscosity of the EVA polymer or cycloolefin polymer.

In embodiments where the intermediate unit polymers used to form the laminate VIG unit are EVA and/or COP, the heating substep b) of process step 3) of the method of the present invention will preferably be carried out at a temperature of 90°C to 150°C, more preferably at a temperature of 110°C to 145°C. These temperature ranges allow optimal crosslinking of the intermediate unit polymers, allowing optimal adhesion and durability.

In embodiments in which the intermediate unit polymer used to form the laminate VIG unit is EVA and/or COP, the sub-steps of processing step (3) include:
a) evacuating to a vacuum of minus 0.1 bar to minus 1 bar, preferably minus 0.5 bar to minus 1 bar in a vacuum ring or vacuum bag at room temperature for a period of 5 minutes to 40 minutes, preferably 10 minutes to 30 minutes, more preferably 20 minutes to 30 minutes;
b*) heating to an intermediate temperature in the range of 75°C to 95°C, preferably for a period of 10 to 60 minutes, more preferably 15 to 40 minutes;
b) heating to a temperature in the range of 110°C to 145°C, preferably 130°C to 140°C, for a period of 45 minutes to 300 minutes;
This is realized in the processing order.

In a further preferred embodiment, the pressurization substep 3)c) is carried out under an overpressure (OP) of 2.0 bar or less (OP≦2.0 bar), preferably 1.5 bar or less (OP≦1.5 bar), preferably 1.0 bar or less (OP≦1.0 bar), preferably 0.5 bar or less (OP≦0.5 bar), more preferably under no overpressure of 0 bar (OP=0 bar).

Preferably, the heating substep b) and the pressure applying substep c) of process step 3) are initiated simultaneously.

All of these preferred features are combined in a further preferred method of the present invention, in which the intermediate unit polymer is EVA and/or COP, preferably EVA.

Processes with Ionomers In processes of the present invention where the intermediate unit polymer used to form the laminate VIG assembly is an ionomer, special consideration must be given to storage of such ionomers at the humidity and temperature conditions recommended by the supplier, usually 15% relative humidity or less.

The process of the present invention, in which the intermediate unit polymer is an ionomer, preferably requires a degassing step and an edge pre-sealing step. In practice, it is preferred that the air located at the VIG and functional unit interface between the intermediate unit polymer is evacuated and then the edges are pre-sealed to avoid air penetration in the processing steps of the process of the present invention. Such an initial degassing step can be achieved by a system of pressure rollers or calenders (single or double) or by a vacuum method. In the present specification, the vacuum method is preferred to avoid deterioration of the mechanical resistance and to maintain the integrity of the laminate VIG assembly.

In this embodiment, the heating substep b) of the process step (3) is preferably carried out for a period of 45 to 75 minutes, more preferably for 60 minutes, at a temperature of preferably 90°C to 150°C, more preferably 130°C to 135°C.

Intermediate Unit Polymer In a preferred embodiment, a suitable intermediate unit polymer to be used in the process of the present invention is selected from the group consisting of ethylene vinyl acetate (EVA), cycloolefin polymer (COP), autoclave-free polyvinyl butyral (hereinafter referred to as autoclave-free PVB), polyurethane (PU), ionomers such as SentryGlas™, and combinations thereof. In a further preferred embodiment, the intermediate unit polymer is selected from the group consisting of ethylene vinyl acetate (EVA) and/or autoclave-free PVB.

The thickness of the intermediate unit polymer is not particularly limited as long as the laminated VIG assembly passes the high temperature test of ISO 12543-4:2011 at an overpressure of 4.5 bar or less and as long as the transparency of the laminated VIG assembly is maintained, but may be, for example, 0.25 mm to 5 mm, preferably 0.3 mm to 4 mm, preferably 0.3 to 3 mm, and more preferably 0.3 mm to 2 mm.

Preferably, when used in the process of the present invention, the intermediate unit polymer is an autoclave-free PVB. As will be appreciated by those skilled in the art, an autoclave-free PVB is a PVB that is effective in lamination processes even at moderate overpressures, i.e., OP ≦4.5 bar (OP≦4.5 bar), preferably OP ≦4.0 bar (OP≦4.0 bar), preferably OP ≦3.0 bar (OP≦3.0 bar), preferably OP ≦2.0 bar (OP≦2.0 bar), preferably OP ≦1.5 bar (OP≦1.5 bar), preferably OP ≦1.0 bar (OP≦1.0 bar), preferably OP ≦0.5 bar (OP≦0.5 bar), or even more preferably equal to 0 bar (OP=0 bar).

A suitable autoclave-free PVB is the PVB interlayer described in paragraphs [0020] to [0026] of WO 2003/057478 by Eastman, which has a low water content of less than 0.35% by weight, an operating temperature range of 120-150°C, preferably 135°C, and allows the lamination process to be realized without an autoclave finishing process. Such autoclave-autoclave-free PVB sheets are commercially available from Eastman as "Saflex@" interlayers. Other suitable autoclave-free PVBs are commercially available from Kuraray, with "Trosifol®" PVB films being recommended for autoclave-free processing, particularly Trosifol® HR.

Furthermore, it has been found that the use of autoclave-free PVB as a suitable intermediate unit polymer provides the required lamination properties at moderate overpressures while also providing excellent transparency and improved strength for safety and security performance.

Preferably, when used in the method of the present invention, the intermediate unit polymer is a polyurethane (PU). A suitable commercially available PU is Krystalflex® TPU film (PE399 or PE900) by Huntsman, which is a high performance aliphatic polyether film recommended for glass, polycarbonate, acrylic, CAB lamination applications and for the aerospace, transportation, security, and construction markets. It offers low temperature impact resistance, excellent adhesion to glass, polycarbonate (PC), and polymethyl methacrylate (PMMA), moisture resistance, low lamination temperature compatible with PMMA, and lamination is possible even for complex surfaces with double curvature.

Preferably, when used in the method of the present invention, the intermediate unit polymer is ethylene vinyl acetate. EVA is preferred because it not only has excellent transparency and flexibility, but also provides improved scattering resistance. Moreover, it can be used at relatively low process temperatures.

Suitable commercially available EVAs are:
- EVA-based lamination films from the supplier GLAAST are specially designed for "glass lamination", in which the DAYLIGHT EV200 series is characterized by very high performance in aging, high static load capacity, adhesion, flow and impact resistance, transparency, high light transmission and exceptional UV protection properties.
Another suitable EVA to be used in the method of the invention is STRATO® PLUS EVA from the supplier Satinal, which offers a completely natural and neutral looking glass due to its high level of transparency and UV protection without distortion or bubble problems, which at the same time guarantees the highest level of transparency even in the case of low temperature lamination.
Also suitable is the Evalam Visual from the supplier HORNOS Pujol.

Preferably, when used in the process of the present invention, the intermediate unit polymer is a cycloolefin polymer. COPs are fully amorphous and highly transparent thermoplastics. Commercially available COPs are sold by supplier Zeon under the name Zeonx®. They offer high transparency and low optical birefringence, low haze, extremely low water absorption and moisture penetration, high heat resistance, high mechanical stiffness, outstanding dimensional stability, good impact resistance, and good moldability, high flow capacity, low mold shrinkage.

Preferably, when used in the method of the present invention, the intermediate unit polymer is an ionomer. Ionomers are plasticizer-free and based on ionoplast chemistry. Ionomers provide structural performance over a range of temperatures due to their unique chemistry. Ionomers are preferred due to their excellent mechanical properties, high strength, strong stability, and moisture resistance. Ionomer laminated glass is colorless, transparent, and UV resistant.

A suitable commercially available ionomer is SentryGlas® ionomer, which is up to 100 times stiffer and up to 5 times stronger than conventional interlayers, helping relatively thin laminates meet prescribed wind loads or structural requirements. Laminated glass made with stiff SentryGlas® can withstand high stress loads.

The functional unit is processed in a process separate from the manufacturing process of the laminated VIG assembly. It is processed at a processing pressure (PP) of 5.5 bar to 15.0 bar (5.5 bar > PP > 15.0 bar), preferably 7.5 bar to 14.0 bar (7.5 bar > PP > 14.0 bar), more preferably 10.0 bar to 14.0 bar (10.0 bar > PP > 14.0 bar).

As described below, the functional unit (4) of the laminated VIG assembly of the present invention typically comprises at least one sheet and a functional layer (43), preferably at least two sheets (41, 42) separated by a functional layer (43). In a preferred embodiment, at least one of the sheets is a glass sheet, more preferably at least two sheets are glass sheets. The functional layer is typically a polymer interlayer and/or an intumescent material. Thus, such a functional unit provides a functional benefit such as safety, security, an acoustic interlayer, solar control, and/or fire protection, etc.

It has been found that functional units made under high pressure lamination processes cannot be laminated directly to VIG because VIG cannot be further processed at such high pressures to retain its physical integrity and functionality. Thus, the method of the present invention allows for the design of laminated VIG assemblies that provide highly efficient functional benefits in addition to the high thermal insulation properties of VIG that are otherwise not obtainable by low pressure lamination processes. In fact, the present invention allows for functional units processed at high pressure to be added to VIG via lamination processes at low pressure. In addition, it has been found that such processes at moderate overpressure maintain the performance and properties of the functional units.

Depending on the performance expected in the laminated VIG assembly of the present invention, different functional units can be laminated to the VIG to provide different functions. For example, in the case of boat applications, it is highly desirable to combine fire and explosion protection, or in the case of urban windows, it is highly desirable to combine acoustic and safety performance. Thus, several of the same or different functional units can be laminated to one or both sides of the VIG.

The functional units can be prepared according to any method known in the art.

In one embodiment of the invention, the functional unit is a safety and/or security functional unit. The primary function of safety and security glass is to absorb energy, such as that generated by an impact from an object, without allowing penetration through the opening, minimizing damage or injury to objects or persons within the enclosed area. Thus, the safety and/or security laminating unit provides protection from injury due to accidental impact, protection from falling through glass, and protection from intrusion and vandalism.

Depending on the expected performance, the safety and/or security functional unit may have two or more glass sheets, each separated by a polymer interlayer. Typically, a person skilled in the art will design a safety and/or security functional unit with a number of glass sheets ranging from 2 to 8, preferably 2 to 4, with glass sheet thicknesses ranging from 0.2 mm, preferably 0.5 mm, preferably 1 mm, more preferably 3 mm, up to 12 mm, preferably 6 mm, and polymer interlayer thicknesses ranging from 0.2 mm, preferably 0.35 mm, up to 5 mm, preferably 2.5 mm.

Typical polymer interlayers to be used in such functional units include materials selected from the group consisting of ethylene vinyl acetate (EVA), polyisobutylene (PIB), polyvinyl butyral (PVB), polyurethane (PU), polyvinyl chloride (PVC), polyester, copolyester, polyacetal, cycloolefin polymer (COP), ionomers, and/or UV-activated adhesives, as well as others known in the art of glass laminate manufacturing. Preferably, the polymer interlayer is polyvinyl butyral. Reinforced sound insulation can be provided by polymer interlayers with specific acoustic performance, such as certain PVBs.

The EN 356 standard defines eight performance levels based on tests that describe the ability of laminated glass panes to resist thrown objects, with levels P1A to P5A corresponding to protection from impacts, including vandalism and theft attempts, and levels P6B to P8B corresponding to reinforced protection from theft attempts. Typically, in case of impact from the external environment, a security function unit has a P1A security level due to a laminate unit having two glass sheets of 3 mm each joined by a polymer interlayer of polyvinyl butyral of 0.76 mm thickness. A typical P2A level would be obtained by a security function unit having a polyvinyl butyral interlayer of 0.76 mm thickness and two glass sheets of 4 mm each. The thickness of the polyvinyl butyral interlayer can be increased to a thickness of 1.52 mm for P4A and to 2.28 for P5A level. To meet EN356 standard levels P6B to P8B, security function units typically have glass panes that are greater than 8mm thick.

In other embodiments, a security feature unit to be used in the method of the present invention may have two sheets of glass, each 4 mm, or each 6 mm, or possibly each 8 mm, laminated with 0.76 mm PVB. Such a unit may be laminated through the method of the present invention to a VIG, which typically has two panes of glass, 4 mm and/or 6 mm thick.

In one embodiment of the present invention, the functional unit is an acoustic functional unit. In an embodiment of the present invention where the method is used to manufacture an acoustic laminate VIG assembly, the VIG and/or the acoustic functional unit are preferably manufactured from glass panes/glass sheets of different thicknesses. In fact, the asymmetric configuration helps block sound wave penetration around the critical audio frequency of the glass, meaning the resonant frequency that would result in spontaneous vibration of the glass.

Also, a typical acoustic functional unit could have two or more glass sheets separated by a polymer interlayer having specific acoustic performance, such as a specific polyvinyl butyral component, for example a Saflex® acoustic PVB interlayer from Eastman or a Trosifol® acoustic PVB layer from Kuraray.

Typically, the acoustic functional unit has two glass sheets, preferably glass sheets of different thickness ranging from 0.2 mm, preferably 0.5 mm, 1 mm, 3 mm, 4 mm to 12 mm, 8 mm, 6 mm. The thickness of the polymer interlayer ranges from 0.2 mm, preferably 0.35 mm to 5 mm, preferably 3 mm.

In some embodiments, an acoustic functional unit to be used in the method of the present invention may have two glass sheets, preferably of different thicknesses, each 4 mm, or each 6 mm, or possibly 8 mm, each laminated with 0.76 mm acoustic PVB. Such a unit may be laminated through the method of the present invention to a VIG with two glass panes of normal thickness of 4 mm and/or 6 mm, preferably of different thicknesses of 4 mm and 6 mm.

In another embodiment of the invention, the functional unit is a bulletproof or explosion-proof unit. To achieve enhanced security protection against theft attempts corresponding to the standard EN 356 and possibly fire and explosions corresponding to the standards EN 1063 and EN 13541, respectively, functional glass units are conventionally designed to have several glass sheets combined with potentially structural plastic sheets, often of different thicknesses, assembled with several PVB and/or polyurethane polymer interlayers.

Such bulletproof and explosion-proof functional units usually have 2 to 10 sheets, preferably 2 to 7 sheets, and at least a corresponding layer of polymer interlayer. Preferably, the sheets are glass sheets or structural plastic sheets, preferably polycarbonate sheets. Typical polymer interlayers to be used in such applications have materials selected from the group consisting of ethylene vinyl acetate (EVA), polyisobutylene (PIB), polyvinyl butyral (PVB), polyurethane (PU), polyvinyl chloride (PVC), polyester, copolyester, polyacetal, cycloolefin polymer (COP), ionomers, and/or adhesives activated by ultraviolet light, and others known in the art of manufacturing glass laminates. Preferably, the polymer interlayer is polyurethane and/or polyvinyl butyral. Reinforced sound insulation can be provided by polymer interlayers with specific acoustic performance, such as certain PVBs. Typical thicknesses for these polymer interlayers are from 0.2 mm, preferably 0.3 mm, more preferably 0.75 mm to 4.5 mm, preferably 3.0 mm, more preferably 1.75 mm.

In one embodiment, the functional unit comprises at least one structural plastic sheet, preferably a polycarbonate sheet, more preferably polycarbonate having a thickness of up to 2.0 mm, and at least one glass sheet laminated with at least one polyvinyl butyral polymer interlayer and at least one polyurethane polymer interlayer. Preferably, the polymer interlayer has a thickness of at least 0.76 mm.

In one embodiment of the present invention, the functional unit is a special solar control functional unit. The functional unit can provide solar benefits that cannot be provided by existing coating layers normally provided on glass sheets. The special solar functional interlayer polymer can provide protection from UV radiation, or can allow the full natural spectrum of solar radiation for plant applications, or can absorb infrared (IR) light wavelengths from the sun.

The solar functional unit typically has at least two glass sheets separated by a solar functional interlayer polymer. Typically, the solar functional unit will have 2 to 8, preferably 2 to 4, glass sheets, where the thickness of the glass sheets ranges from 0.2 mm, preferably 0.5 mm, preferably 1 mm, more preferably 3 mm to 12 mm, preferably 6 mm, and the thickness of the solar interlayer polymer ranges from 0.2 mm, preferably 0.35 mm to 5 mm, preferably 2.5 mm.

Suitable solar-functional interlayer polymers are, for example, PVB and XIR foil (metallic coating on PET laminated between layers of polyvinyl butyrate) contained within a layer of IR-cut PVB (particles of indium tin oxide (ITO) or cesium tungsten oxide (ceWox) particles dispersed within a layer of polyvinyl butyrate). Commercially available solar-functional interlayer polymers are Saflex® solar range interlayer from supplier Eastman, Southwall's XIR® laminate product encapsulating an XIR "heat rejecting" film between two layers of PVB and glass, and S-LEC™ Sound and Solar Film from supplier Sekisui.

Preferably, the laminated VIG assembly produced by the method of the present invention will combine several functions: safety/security, acoustics, bullet/explosion proof, and/or special solar control, preferably safety/security and acoustics. Thus, in one preferred embodiment, the functional unit comprises at least two glass sheets laminated with a polyvinyl butyral polymer interlayer. Preferably, in another preferred embodiment, the functional unit comprises at least one polycarbonate sheet and at least one glass sheet laminated with at least one polyvinyl butyral polymer interlayer and at least one polyurethane polymer interlayer. Preferably, the polyvinyl butyral polymer interlayer is an acoustic polyvinyl butyral polymer interlayer and/or the sheets have different thicknesses.

In one embodiment of the present invention, the functional unit is a fire-resistant functional unit. A fire-resistant functional unit usually comprises at least two sheets of glass separated by a layer of intumescent material. The weight and thickness of the fire-resistant glazing can be large, depending on the number of glass sheets and the required fire performance level that defines the layer of intumescent material. The layer of intumescent material is most often composed of hydroxide alkali metal silicates. Alternatively, organic and/or inorganic hydrogels may be used. Under the effect of heat, the intumescent material expands by forming a foam opaque to radiation that keeps the glass walls in place even when fragmented under the effect of heat.

The use of alkali metal hydroxide silicates in the manufacture of fire-retardant functional units is mainly carried out according to two distinct modes. The first mode is called the "drying process", since such fire-retardant functional units are usually treated in two stages, with a first drying stage followed by an autoclave stage, usually at a temperature of about 110°C and a pressure of 11-13 bar.

In the first mode, a layer of intumescent material is obtained by applying a solution of these silicates on a glass pane and performing a rather long drying step until a solid layer is obtained. Several assembly layers/glass panes can be laminated to obtain a product with the desired fire retardant properties. The last layer of intumescent material formed is usually covered by a final glass sheet.

In such a first mode, the fire-retardant functional unit preferably comprises 2 to 9 glass sheets, more preferably 3 to 5 glass sheets. Such glass sheets are preferably 3 mm to 8 mm thick, and the layer of intumescent material is preferably 1 to 8 mm, preferably 1 to 5 mm, more preferably 1 to 4 mm thick.

In a preferred embodiment, the fire retardant functional unit has three glass sheets and two layers of intumescent material. Typically, such a fire retardant unit will have a 3mm first glass sheet + 1.5-2mm intumescent material + 8mm second glass sheet + 1.5-2mm intumescent material + 3mm third glass sheet. Typically, such a fire retardant unit can be laminated to a VIG, such as a VIG with two glass panes of 6mm each, via an intermediate unit polymer such as 0.76mm EVA.

In another preferred embodiment, the fire resistant functional unit has 5 glass sheets and 4 layers of intumescent material. Typically, such a fire resistant unit would have a 3mm first glass sheet + 1.5-2mm intumescent material + 3mm second glass sheet + 1.5-2mm intumescent material + 8mm third glass sheet and then 2 3mm glass sheets separated again by 1.5-2mm intumescent material. Typically, such a fire resistant unit can be laminated to a VIG such as a VIG with 2 glass panes of 6mm each via an intermediate unit polymer such as 0.76mm EVA.

In another preferred embodiment, the fire resistant unit has two glass sheets, two panes of glass, each 3 mm, separated by a layer of intumescent material of 1.5-2 mm, and one layer of intumescent material. Typically, such a fire resistant unit can be laminated to a VIG, such as a VIG with two panes of glass, each 6 mm, via an intermediate unit polymer, such as EVA, 0.76 mm.

It may be envisaged to use glass panes and sheets of different thicknesses for improved acoustic properties.

The second mode is called the "cast-in-place method", because such fire-resistant functional units are usually processed in two stages: a first assembly stage, usually at ambient temperature, in which the double glazing with peripheral spacers is produced at a pressure of up to 20 bar, creating a space into which the intumescent material is poured, followed by a stage of reticulation of the intumescent material, usually at temperatures of around 70-90°C and atmospheric pressure.

In this second mode of fire-retardant functional units, the silicate solution is modified by the addition of products qualifying as "hardeners", "crosslinkers" or in another way to accelerate the gelation of the silicate solution. These are carefully selected so that after their addition to the silicate solution, the silicate solution, when left at rest, hardens spontaneously as an intumescent layer in a relatively short time without the need to carry out a drying step. In the case of these products, before the formation of the gel, the solution and its final additives are poured into a cavity between two glass panes. The glass panes are joined at their periphery by a spacer that defines a leak-proof cavity into which the solution is poured with the two glass panes maintaining themselves at a certain distance from each other.

In such a second mode, the fire-retardant functional unit preferably comprises 2 to 4 glass sheets. Such glass sheets are preferably 3 mm to 6 mm thick, and the layer of intumescent material is preferably 3 to 30 mm thick.

In one preferred embodiment of such second mode, the fire resistant functional unit has two glass sheets and one layer of intumescent material. Typically, such a fire resistant unit will have a 6mm first glass sheet, preferably tempered, + 4-6mm intumescent material + 6mm second glass sheet, preferably tempered. Typically, such a fire resistant unit can be laminated to a VIG, such as a VIG with two glass panes of 6mm each, via an intermediate polymer such as 0.76mm EVA.

In the method of the present invention, in which the functional unit is a second mode of a fire-retardant functional unit, i.e. having at least two glass sheets separated by a peripheral spacer to create a space with the intumescent material, the heating substep b) of the process step 3) is preferably realized at a temperature of not more than 120°C, preferably not more than 110°C, preferably not more than 100°C, more preferably not more than 90°C.

Other Functional Units Several other additional benefits can be imparted to the functional units, including fairly delicate technology that cannot withstand further processing at high temperatures and/or pressures, which can also be produced by the methods of the present invention.

They are functional unit panes with electrochromic, thermochromic, photochromic or photovoltaic elements, which are also compatible with the present invention. Other suitable electronic functional units to be used in the present invention are LEDs (light emitting diodes) - monochrome or RGB (red, green, blue) - powered through a highly efficient transparent conductive layer. Further electronic functional units can have displays, antenna systems capable of sending and receiving electromagnetic signals, contact functions, etc. Others are decorative functional units, usually with decorative inserts of paper, fabric, stone-like films into a PVB frame.

V.I.G.
The vacuum insulating glazing (2) of the laminated VIG assembly (1) produced by the method of the present invention is usually
a first glass pane (21) and a second glass pane (21),
a set of discrete spacers (23) arranged between the first and second glass panes to maintain the distance between them;
- a hermetic joint seal (24) sealing the distance between the first and second glass panes across their border;
an internal volume V defined by the first and second glass panes and the set of discrete spacers, closed by a hermetic bonded seal, in which an absolute vacuum exists with a pressure of less than 0.1 mbar;
has.

Generally, to achieve high performance insulation (thermal transmission coefficient U<1.2 W/ ^m2K , preferably U<0.8 W/ ^m2K ), the pressure inside the glazing unit is usually below 0.1 mbar and generally at least one of the two glass panes is covered by a low-E coating.

Method of Manufacturing a Glass Pane Unit There are different methods for assembling a VIG. An exemplary assembly method is described in EP 2851351 A1, which has three main steps that may overlap. First, the first glass pane is placed horizontally, the glass frit is deposited, the pillars are placed, the second pane is placed on top, and a first heating period (up to 450° C.) allows the hermetic sealing of both glass panes at their outer edges, leaving a space between them. The second step is the pumping of the inner gas to a residual pressure of less than 0.1 mbar. In connection with the formation of a vacuum in the internal space of the glass unit, a hollow glass tube is provided, generally on the main surface of one of the glass sheets, which connects the internal space to the outside. Thus, a vacuum is created in the internal space by pumping the gas present into the internal space with the aid of a pump connected to the outer end of the glass tube. For example, European Patent Application Publication No. EP 1506945 A1 describes the use of such a glass tube, which is welded in place in a through hole provided in the main face of one of the glass sheets. In this second step, the temperature is reduced to a certain extent and the glass panes are brought close enough to reach the pillars that define the autoclave-free space. The final space between the two glass panes is no more than 2 mm. The third step involves a second heating period up to 465° C., allowing the pillars to adhere to the glass panes and completing the hermetic seal. This technique degrades the aesthetic appearance of the glass panes, since no visible protrusions are formed on the surface of one of the glass sheets.

Also suitable is the manufacturing method described in WO 2019/230220, including the joining steps [0011]-[0025], the insertion steps [0026]-[0027], the depressurization steps [0028]-[0043], and the sealing steps [0044]-[005], as well as the variations of such steps described below. The process temperature is about 300° C. or less, allowing the processing of vacuum insulated glazing with heat strengthened and heat toughened glass panes.

Spacers Discrete spacers (also called "pillars") are placed between the first and second glass panes, maintaining the distance therebetween, forming an array with a pitch λ between 10 mm and 100 mm (10 mm≦λ≦100 mm). Pitch means the interval between the discrete spacers. In a preferred embodiment, the pitch is between 20 mm and 80 mm (20 mm≦λ≦80 mm), more preferably between 20 mm and 50 mm (20 mm≦λ≦50 mm). The array in the present invention is a regular array, usually based on an equilateral triangular, square or hexagonal scheme, preferably based on a square scheme. The discrete spacers can have different shapes, like cylindrical, spherical, thread-like, hourglass, C-shaped, cross-shaped, prism-shaped, etc. It is preferred to use small pillars, i.e. pillars having a contact surface towards the glass pane as a whole defined by their circumference of ⁵ mm2 or less, preferably ³ mm2 ^or less, more preferably 1 mm2 or less. These values can provide good mechanical resistance while being aesthetic.

Conventional discrete spacers are manufactured from materials that have the strength to withstand the pressures and high temperatures that generate the VIG process and that do not outgas after the glass pane is manufactured. Such materials are preferably hard materials such as metallic materials, quartz glass, or ceramic materials, especially metallic materials such as iron, tungsten, nickel, chromium, titanium, molybdenum, carbon steel, chromium steel, nickel steel, stainless steel, nickel-chromium steel, manganese steel, chromium-manganese steel, chromium-molybdenum steel, silicon steel, nichrome, duralumin, or the like. Another such material is a ceramic material such as corundum, alumina, mullite, magnesia, yttria, aluminium nitride, silicon nitride, or the like. However, while such materials offer relatively high mechanical resistance, they offer rather poor performance in terms of thermal conductivity. Therefore, the preferred discrete spacers for the VIG elements of the laminated VIG assembly of the present invention are made from a material with a relatively low conductivity profile, such as a resin preferably made from a polyimide resin. In this case, it is possible to suppress the thermal conductivity of the spacers, and heat is not transferred through the discrete spacers in contact with the first and second glass sheets.

Hermetic joint seal The internal volume of the VIG is closed by such a hermetic joint seal arranged at the periphery of the glass pane around said internal space. The hermetic joint seal has impermeability to air or any other gas present in the atmosphere. There are various hermetic joint seal technologies. The first type of seal (the most widely used) is a seal based on a solder glass whose melting point is lower than that of the glass of the glass pane of the glazing unit. This is usually below 500°C, preferably below 450°C, more preferably below 400°C. Examples are low melting point glass frits such as bismuth-based glass frits, lead-based glass frits and vanadium-based glass frits and mixtures thereof. The second type of seal comprises a metallic seal, for example a metal strip of small thickness (<500 μm) soldered to the periphery of the glazing unit by a tie-under layer at least partially covered by a layer of solderable material such as a soft tin alloy solder.

Inner Volume In the inner volume V defined by the first and second glass panes and the set of discrete spacers and closed by the hermetically bonded seal in the VIG, a vacuum is created with an absolute pressure of less than 0.1 mbar, preferably less than 0.01 mbar. To maintain a given vacuum level in the vacuum insulating glazing unit for a sustained period of time, getters can be used. Typically, such getters are made of alloys of zirconium, vanadium, iron, cobalt, aluminum, etc., and are deposited in the form of a thin layer (a few microns thick) or in the form of a block placed between the glass panes.

Panes and Sheets The panes and functional units of the VIG can be selected from glass, metal sheets, or structural plastic sheets such as polycarbonate sheets for reduced weight, preferably from float clear, extra clear, or tinted glass. The glass panes can optionally have polished edges for safety purposes. Preferably, the panes and functional units of the VIG according to the invention are made of glass, usually soda-lime silica glass, aluminosilicate glass, or borosilicate glass, preferably soda-lime silica glass. Textured, structured, printed glass is suitable. For acoustic performance, it is preferred that the glass panes of the VIG and the sheets of the functional intermediate units have different thicknesses. It is also preferred that the glass panes of the VIG have different thicknesses to improve resistance to induced thermal stresses in the VIG during use, where the glass panes are exposed to temperature differences between the external and internal environments, and to reduce L _use .

Typically, the glass panes/sheets are annealed glass panes/sheets. However, in order to provide a laminated VIG assembly with relatively high mechanical performance and/or to further improve the safety of the VIG and/or functional units, it may be envisaged to use prestressed glass for one or more glass panes of the laminated VIG assembly and/or for one or more glass sheets of the functional units. Prestressed glass means in this specification heat strengthened glass, heat toughened safety glass or chemically strengthened glass.

Heat-strengthened glass is heat-treated using a controlled heating and cooling method that places one glass surface under compression and the other under tension. This heat treatment method gives the glass a bending strength greater than that of annealed glass, but less than that of heat-toughened safety glass.

Heat-toughened safety glass is heat-treated using a controlled heating and cooling method that places one glass surface under compression and the other under tension. Such stresses cause the glass to break into small granular particles upon impact, instead of scattering into jagged shards. The granular particles are less likely to injure occupants or damage objects.

Chemical strengthening of glass articles is a thermally induced ion exchange involving the replacement of relatively small alkali sodium ions in the surface layer of the glass with relatively large ions, such as, for example, alkali potassium ions. Increased surface compressive stresses are generated in the glass as the relatively large ions are "wedge" into the small sites previously occupied by the sodium ions. Such chemical treatment is typically carried out by immersing the glass in an ion exchange melting bath containing one or more molten salts of the relatively large ions with precise control of temperature and time. Aluminosilicate type glass compositions, such as those from the DragonTrail® family of products from Asahi Glass Co. or the Gorilla® family of products from Corning Inc., are also known to be very efficient for chemical strengthening.

Preferably, the composition for the glass pane/sheet has the following components in weight percentages expressed relative to the total weight of the glass (Comparative Example A): More preferably, the glass composition (Comparative Example B) is a soda lime silicate type glass having a base glass matrix of a composition having the following components in weight percentages expressed relative to the total weight of the glass:

Other suitable glasses have the following components in weight percentages expressed relative to the total weight of the glass:

In some embodiments of the present invention, a film such as a low emissivity film, a solar control film (heat reflective film), an anti-reflective film, an anti-fog film, preferably a heat reflective film or a low emissivity film, can be provided on the glass sheets in the functional block and ultimately on at least one of the glass panes of the VIG.

Figure 1 shows a laminated VIG assembly (1) having a VIG (2) and a functional unit (4) laminated by the method of the present invention through an intermediate unit polymer (3). The VIG (2) has a first glass pane (21) and a second glass pane (21) and a set of individual spacers (23) positioned between the first and second glass panes to maintain the distance therebetween. It is closed by a hermetic joint seal (24) that seals the distance between the first and second glass panes across its border and thus defines an internal volume V, inside which there is an absolute vacuum with a pressure of less than 0.1 mbar. A low-emissivity film or a heat-reflecting film (5) is provided on the inner surface pane of the second glass pane of the VIG. The functional unit (4) has a first glass sheet (41) laminated to a second glass sheet (42) by an intermediate layer polymer (43).

Those skilled in the art understand that the present invention is in no way limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims. It should be noted further that the present invention also relates to all possible combinations of the features and preferred features described in this specification and claimed in the claims.

The following examples are provided for illustrative purposes and are not intended to limit the scope of the invention.

Example 1: Acoustic Laminate VIG Assembly An acoustic functional unit with two standard soda lime silica glass sheets (each 8 mm thick) and one acoustic polyvinyl butyral (0.76 mm thick) was produced by standard lamination methods with nip roller and autoclave techniques at a temperature of 140° C. and a pressure of 12 bar.

The VIG has two standard soda-lime-silica glass panes (each 6 mm thick) sealed by glass frit, pillars of resin material with a pitch of 20 mm. The thermal performance of such a VIG(U) is 0.7 W/ ^m2K .

In the autoclave,
1) preparing a pre-assembly by laminating VIG, 0.76 mm of intermediate unit polymer EVA (deposited on the surface of the functional unit), and the functional unit;
2) inserting the pre-assembly into a vacuum bag;
3) processing the preassembly to produce a laminated VIG assembly;
- Evacuation to a vacuum of -1 bar at ambient temperature for 30 minutes;
heating at intermediate temperature of 85-90° C. for 30 minutes under sustained vacuum;
- heating at a temperature of 130° C. for 105 minutes under sustained vacuum;
0.2 bar overpressure (OP=0.2 bar)
4) An acoustic laminate VIG assembly was prepared by releasing the vacuum and heat and releasing the overpressure at ambient temperature such that the laminate VIG assembly reached ambient temperature within 35 minutes.

Acoustic laminate VIG assemblies produced via the method of the present invention have passed high temperature testing to ISO 12543-4:2011 and have demonstrated excellent properties of maintaining the physical integrity of the VIG, particularly around the compressed pillars with no signs of microcracking, maintaining excellent thermal performance, and excellent acoustic properties, as well as achieving this at very limited thicknesses.

Specifically, Table I below shows that the acoustic laminate VIG assembly obtained by the method of the present invention provides superior acoustic properties, better than the acoustic performance of VIG alone and in some cases better than double glazing having two identical units of acoustic functional unit and VIG.

According to ISO 10140-2:2010: Acoustics-Laboratory measurement of sound insulation of building elements-Part 2: Measurement of airborne sound insulation, Rw(C;Ctr), where Rw represents the weighted sound reduction index, C and Ctr are correction factors, i.e., C for the mid-frequency range and Ctr for the low-frequency range. Increasing Rw by 1 corresponds to approximately 1 db reduction in noise level.

Example 2: Security Laminated VIG Assembly A security functional unit comprising two standard soda lime silica glass sheets, each with a thickness of 4 mm, laminated with six layers of PVB, each with a thickness of 0.38 mm, was produced by standard lamination methods with nip roller and autoclave techniques at a temperature of 140° C. and a pressure of 12 bar.

The VIG has two standard soda lime silica glass panes (each 4 mm thick) sealed by glass frit, pillars of resin material with a pitch of 20 mm. The thermal performance of such a VIG(U) is 0.7 W/ ^m2K .

In an oven without overpressure,
1) preparing a pre-assembly by laminating VIG, 0.76 mm of intermediate unit polymer EVA (deposited on the surface of the functional unit), and the functional unit;
2) inserting the pre-assembly into a vacuum bag;
3) processing the preassembly to produce a laminated vacuum insulated glazing assembly;
- Evacuation to a vacuum of -1 bar at ambient temperature for 30 minutes;
heating at intermediate temperature of 85-90° C. for 30 minutes under sustained vacuum;
- heating at a temperature of 130 degrees for 80 minutes under sustained vacuum;
- No overpressure (OP = 0 bar)
4) releasing the vacuum and heat so that the laminated VIG assembly reaches ambient temperature within 30 minutes;
A security laminate VIG assembly was manufactured by

Security laminate VIG assemblies produced via the method of the present invention have passed high temperature testing to ISO 12543-4:2011 and have demonstrated excellent properties in maintaining the physical integrity of the VIG, particularly around the compressed pillars, with no signs of microcracking, excellent thermal performance maintenance, and excellent security properties.

Specifically, Table II below shows that the laminated VIG assembly obtained by the method of the present invention provides superior security properties. A VIG made from two glass sheets, each 4 mm, does not demonstrate mechanical performance per EN 356. When laminated into a security function unit, the laminated VIG made by the method of the present invention demonstrates a P5A classification under security standard Ref. No. EN 356:1999 E.

Claims (23)

A method for manufacturing a laminated vacuum insulation glazing assembly (1) that meets the high temperature test standard ISO 12543-4: 2011, comprising at least:
1) laminating a vacuum insulation glazing (2), an intermediate unit polymer (3) and a functional unit (4) thereby producing a preassembly, wherein said functional unit is processed at a processing pressure (PP) of 5.5 bar to 15.0 bar (5.5 bar > PP > 15.0 bar), preferably 7.5 bar to 14.0 bar (7.5 bar > PP > 14.0 bar), more preferably 10.0 bar to 14.0 bar (10.0 bar > PP > 14.0 bar),
2) inserting the pre-assembly into a vacuum ring or vacuum bag, preferably into a vacuum bag;
3) At a minimum,
a. evacuating the inside of the vacuum ring or vacuum bag to a vacuum of minus 0.1 bar to minus 1 bar, preferably minus 0.5 bar to minus 1 bar;
b. heating the preassembly to a temperature in the range of 50° C. to 200° C., preferably 75° C. to 175° C., more preferably 90° C. to 150° C.;
c) pressurizing the preassembly under an overpressure (OP) of 4.5 bar or less (OP≦4.5 bar);
processing the pre-assembly to produce a laminated VIG assembly by
4) releasing the exhaust 3) a), the heating 3) b), and the overpressure 3) c);
A method comprising: The method for manufacturing a laminated vacuum insulated glazing assembly according to claim 1, wherein the functional unit includes at least two sheets, preferably at least one of the sheets being a glass sheet, and more preferably the at least two sheets being glass sheets. The method for manufacturing a laminated vacuum insulation glazing assembly according to claim 1 or 2, wherein the overpressure in sub-step 3)c) is equal to or less than 4.0 bar (OP≦4.0 bar), preferably equal to or less than 3.0 bar (OP≦3.0 bar), preferably equal to or less than 2.0 bar (OP≦2.0 bar), preferably equal to or less than 1.5 bar (OP≦1.5 bar), preferably equal to or less than 1.0 bar (OP≦1.0 bar), preferably equal to or less than 0.5 bar (OP≦0.5 bar), and more preferably equal to 0 bar (OP=0 bar). The method for manufacturing a laminated vacuum insulation glazing assembly according to any one of claims 1 to 3, wherein the sub-steps of the processing step 3) are realized in the processing order of the evacuation sub-step 3)a), the heating sub-step 3)b), and the pressurizing sub-step 3)c), and preferably the heating sub-step 3)b) and the pressurizing sub-step 3)c) are started simultaneously. The method for manufacturing a laminated vacuum insulation glazing assembly according to any one of claims 1 to 4, wherein the evacuation sub-step 3)a) of the processing step 3) is carried out at ambient temperature for a period of 5 to 40 minutes, preferably 10 to 30 minutes, more preferably 20 to 30 minutes. The method for manufacturing a laminated vacuum insulation glazing assembly according to any one of claims 1 to 5, wherein the releasing step 4) is preferably achieved by first releasing the heating and then releasing the exhaust, preferably releasing the exhaust and pressure together, when the temperature of the VIG laminate assembly reaches 50°C to 60°C, more preferably ambient temperature. The method for manufacturing a laminated vacuum insulation glazing assembly according to any one of claims 1 to 6, wherein the heat release step of step (4) is carried out at a rate of 1 to 10°C/min, preferably 2 to 9°C/min, preferably 3 to 8°C/min, preferably 4 to 7°C/min, more preferably 5 to 6°C/min, preferably in a temperature range of 130°C to 30°C. The laminated vacuum insulation glazing assembly satisfies the load formula L _lam ≦[L _int (SF-1)] + [L _use × SF];
- L _lam is the lamination load, which is the total stress caused by laminations on the vacuum insulating glazing,
- L _int is the intrinsic load, which is itself all the stresses inherent in the design of said vacuum insulating glazing,
- SF is the security factor,
A method for manufacturing a laminated vacuum insulation glazing assembly as described in any one of claims 1 to 7, wherein -L _use is a usage load which is all stresses caused by the usage conditions of the vacuum insulation glazing. The method for producing a laminated vacuum insulation glazing assembly according to any one of claims 1 to 8, wherein the intermediate unit polymer is selected from the group consisting of ethylene vinyl acetate (EVA), cyclopolyolefin polymer (COP), autoclave-free polyvinyl butyral (autoclave-free PVB), polyurethane (PU), and/or ionomer, and is preferably selected from ethylene vinyl acetate (EVA) and/or autoclave-free polyvinyl butyral (autoclave-free PVB). The method for manufacturing a laminated vacuum insulation glazing assembly according to any one of claims 1 to 9, wherein the intermediate unit polymer is autoclave-free polyvinyl butyral and the temperature of the heating sub-step b) of the processing step 3) is in the range of 90°C to 150°C, preferably 115°C to 150°C, preferably 135°C to 145°C, more preferably 140°C, for a period preferably in the range of 20 minutes to 180 minutes, more preferably 60 minutes. The method for manufacturing a laminated vacuum insulation glazing assembly according to any one of claims 1 to 9, wherein the intermediate unit polymer is polyurethane and the temperature of the heating sub-step b) of the processing step 3) is in the range of 90°C to 150°C, preferably 110°C to 120°C, for a period preferably in the range of 20 minutes to 180 minutes, more preferably for 60 minutes. The method for manufacturing a laminated vacuum insulation glazing assembly according to claim 11, wherein the pressurizing substep 3)c) is carried out under an overpressure (OP) of 2.0 bar to 4.5 bar (2.0 bar <= OP <= 4.5 bar), preferably 2.0 bar to 4.0 bar (2.0 bar <= OP <= 4.0 bar), more preferably 3.0 bar. The method for manufacturing a laminated vacuum insulation glazing assembly according to any one of claims 1 to 9, wherein the intermediate unit polymer is ethylene vinyl acetate and/or a cyclopolyolefin polymer, preferably ethylene vinyl acetate, and the temperature of the heating sub-step b) of the processing step 3) is in the range of 90°C to 150°C, preferably 110°C to 145°C. The method for manufacturing a laminated vacuum insulation glazing assembly according to claim 13, wherein the treatment step (3) comprises a further substep b*) of heating to an intermediate temperature in the range of 75°C to 95°C, preferably for a period of 10 minutes to 60 minutes, more preferably 15 minutes to 40 minutes, prior to the substep b). The sub-steps of the processing step (3) include:
a) evacuation at room temperature for a period of 5 minutes to 40 minutes, preferably 10 minutes to 30 minutes, more preferably 20 minutes to 30 minutes;
b*) heating to an intermediate temperature in the range of 75°C to 95°C, preferably for a period of 10 minutes to 60 minutes, more preferably 15 minutes to 40 minutes;
b) heating to a temperature in the range of 110° C. to 145° C., preferably 130° C. to 140° C., for a period of 45 min to 300 min;
c) pressurizing under an overpressure (OP) of 2.0 bar or less (OP≦2.0 bar), preferably 1.5 bar or less (OP≦1.5 bar), preferably 1.0 bar or less (OP≦1.0 bar), preferably 0.5 bar or less (OP≦0.5 bar), more preferably under no overpressure of 0 bar (OP=0 bar);
This is achieved in the following processing order:
A method for manufacturing a laminated vacuum insulating glazing assembly according to claim 13 or 14, preferably wherein sub-steps b) and c) are performed simultaneously. The method for producing a laminated vacuum insulation glazing assembly according to any one of claims 1 to 9, wherein the intermediate unit polymer is an ionomer and the heating substep b) of the treatment step (3) is carried out at a temperature of 90°C to 150°C, preferably 130°C to 135°C, for a period of preferably 45 minutes to 75 minutes, more preferably 60 minutes. The method for manufacturing a laminated vacuum insulated glazing assembly according to any one of claims 1 to 16, wherein the functional unit comprises at least two glass sheets laminated with a polyvinyl butyral polymer interlayer. A method for manufacturing a laminated vacuum insulated glazing assembly according to any one of claims 1 to 16, wherein the functional unit comprises at least one structural plastic sheet, preferably a polycarbonate sheet, laminated with at least one polyvinyl butyral polymer interlayer and at least one polyurethane polymer interlayer, and at least one glass sheet. The method for manufacturing a laminated vacuum insulated glazing assembly according to claim 17 or 18, wherein the polyvinyl butyral polymer interlayer is an acoustic polyvinyl butyral polymer interlayer and/or the sheets each have a different thickness. A method for manufacturing a laminated vacuum insulated glazing assembly according to any one of claims 1 to 16, wherein the functional unit comprises at least two glass sheets separated by an intumescent material, preferably an alkali metal hydroxide silicate. The method for manufacturing a laminated vacuum insulated glazing assembly according to claim 20, wherein the functional unit further comprises a peripheral spacer, thereby creating a space between the two glass sheets for containing the expansion material, and the heating sub-step b) of the processing step 3) is realized at a temperature of 120°C or less, preferably 110°C or less, preferably 100°C or less, more preferably 90°C or less. The method for manufacturing a laminated vacuum insulated glazing assembly according to any one of claims 1 to 21, wherein the vacuum insulated glazing includes first and second glass panes, and at least one of the first and/or second glass panes of the vacuum insulated glazing and/or at least one of the multiple sheets of the functional unit is heat strengthened glass, heat toughened safety glass, or chemically strengthened glass. The method for manufacturing a laminated vacuum insulated glazing assembly according to any one of claims 1 to 22, wherein the vacuum insulated glazing has a first glass pane and a second glass pane, and a set of discrete spacers arranged between the first glass pane and the second glass pane to maintain a distance between the first glass pane and the second glass pane, and the discrete spacers are made of a metal material, quartz glass, a ceramic material, and/or a resin, preferably a resin, more preferably a polyimide resin.