1、Glass Engineering: Design Solutions for Automotive ApplicationsOther SAE books of interest Automotive Carbon Composites: From Evolution to Implementation By Jackie D. Rehkopf (Product Code: T-124) Precious Materials Handbook By Dr. Matthias Grehl (Product Code: B-944) Design Review Based on Failure
2、Modes (DRBFM) and Design Review Based on Test Results (DRBTR) Process Guidebooks By Bill Haughey (Product Code: PD251136) For more information or to order a book, contact SAE INTERNATIONAL 400 Commonwealth Drive, Warrendale, PA 15096-0001, USA; phone +1-877-606-7323 (U.S. and Canada only) or +1-724-
3、776-4970 (outside U.S. and Canada); fax +1-724-776-0790; e-mail CustomerServicesae.org; website http:/ /books.sae.org.Glass Engineering: Design Solutions for Automotive Applications By Lyn R. Zbinden Warrendale, Pennsylvania USA 400 Commonwealth DriveWarrendale, PA 15096E-mail: CustomerServicesae.or
4、gPhone: +1.877.606.7323 (inside USA and Canada)+1.724.776.4970 (outside USA)Fax: +1.724.776.0790 Copyright 2014 SAE International. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, distributed, or transmitted, in any form or by any means without the pr
5、ior written permission of SAE International. For permission and licensing requests, contact SAE Permissions, 400 Commonwealth Drive, Warrendale, PA 15096-0001 USA; e-mail: copyrightsae.org; phone: +1-724-772-4028; fax: +1-724-772-9765. SAE Order Number R-433 DOI 10.4271/R-433 Library of Congress Cat
6、aloging-in-Publication Data Zbinden, Lyn R.Glass engineering : design solutions for automotive applications / by Lyn R. Zbinden.pages cm“SAE order number R-433”Title page verso.ISBN 978-0-7680-7999-91. AutomobilesWindows and windshieldsDesign and construction. 2. Glass manufacture. I. Title. TL256.5
7、.Z35 2014629.266dc23 2013048406 Information contained in this work has been obtained by SAE International from sources believed to be reliable. However, neither SAE International nor its authors guarantee the accuracy or completeness of any information published herein and neither SAE International
8、nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that SAE International and its authors are supplying information, but are not attempting to render engineering or other professional servic
9、es. If such services are required, the assistance of an appropriate professional should be sought. ISBN-Print 978-0-7680-7999-9 ISBN-PDF 978-0-7680-8116-9 ISBN-epub 978-0-7680-8118-3 ISBN-prc 978-0-7680-8117-6 To purchase bulk quantities, please contact: SAE Customer Service E-mail: CustomerServices
10、ae.org Phone: +1-877-606-7323 (inside USA and Canada)+1-724-776-4970 (outside USA) Fax: +1-724-776-0790 Visit the SAE International Bookstore HTTP:/ /BOOKS.SAE.ORGDedication To my DadTable of Contents Foreword . xiii Preface xv Acknowledgments . xvii Chapter 1 - Ceramics, Raw Materials, and Processi
11、ng 1 1.1 Materials 1 1.2 Manufacturing Process 2 Chapter 2 - How to Use What We Have Learned 5 Chapter 3 - Glass and Thermal Stress . 7 3.1 Annealing 8 3.2 Toughened Glass 8 3.3 Tempered Glass 8 3.4 Types 9 3.5 Strength . 9 3.6 Processing . 9 Chapter 4 - Forming for Specific Vehicle Positions 11 4.1
12、 Laminated Glass . 11 4.2 Application . 11 4.3 Forming . 11 4.4 Processing . 12 4.5 Added Value . 13 4.6 Construction . 13 4.7 Non-laminated Glass 13 Chapter 5 - Design Guidelines and Applications . 15 5.1 Design Guidelines 15 5.2 Specific Design Applications 19 Chapter 6 - Processing. 21 6.1 Windsh
13、ield/Windscreen Applications . 21 6.2 Windshield and Sidelite Processing 23 Chapter 7 - Ceramic Frit and Shadeband . 27 7.1 The Process . 27 vii 7.2 Composition . 27 7.3 Artwork . 27 7.4 Supplier Capabilities . 27 7.5 Artwork Costs 28 7.6 Manufacture of Frit . . 28 7.7 Artwork Changes . 28 7.8 Shade
14、bands . 28 Chapter 8 - Adhesive Bonding . 29 8.1 Types .29 8.2 Temperature 29 8.3 Interface Control 30 8.4 Locating Scheme 30 8.5 Surface Preparation . 30 8.6 Urethane Adhesive Application 31 8.7 Storage . 31 8.8 Clean-up 31 8.9 Primers 31 Chapter 9 - Moldings, Encapsulation, and Related Opportuniti
15、es . 33 9.1 Molding Types and Materials 33 9.2 Rubber Materials for Extrusion and Molding . 36 9.3 Thermoplastic Extrusion (Plastics) 39 9.4 Plastic Materials for Extrusion and Molding . 40 9.5 Encapsulation . 41 9.6 Reference . 45 Chapter 10 - Installation and Post Processing . 47 10.1 Locating Pin
16、s and Slots 47 10.2 Inspection 47 10.3 Plant Applied Primer 48 10.4 Failure to Prime 48 10.5 Structural Integrity 48 10.6 Quality Control 48 Chapter 11 - Value-Added Engineering 49 11.1 Infrared Reflecting GlassSolar Absorbing . 49 11.2 Photovoltaic Glass . 50 11.3 Heated Glass . 51 viii Table of Co
17、ntents11.4 Laminated Sidelites . 51 11.5 Potential Field Issues . 51 Chapter 12 - Testing Tables 53 Table 12.1 Standard Automotive Water Pressure Testing . 54 Table 12.2 Transit Bus Window Benchmarking 55 Table 12.3 Coding System for Model Numbers Required by ANSI Z 26.11996 . 56 Table 12.4 Tests Ac
18、cording to ANSI Z 26.11996 57 Table 12.5 Sample Design, Validation, Planning, and Responsibility Matrix 58 Table 12.6 Legal Requirements, Test Description, and Accepted Criteria 59 Table 12.7 Legal Requirements, Test Description, and Accepted Criteria 60 Table 12.8 Failure Mode Effects and Analysis
19、61 Table 12.9 How to Conduct Your Design Review 62 Chapter 13 - Common Glazing Terms 63 Chapter 14 - Design Rule Tables . 71 Table 14.1 Blank Size 71 Table 14.2 Forming a Laminated Windshield . 72 Table 14.3 Forming a Sidelite 72 Table 14.4 Windshield Shape . 73 Table 14.5 Horizontal Depth of Chord
20、. 73 Table 14.6 Vertical Depth of Chord. 74 Table 14.7 Pillar Rise . 74 Table 14.8 Pillar Radius 74 Table 14.9 Ceramic Frit . 75 Table 14.10 Corner Radii 75 Table 14.11 Flange Length . 76 Table 14.12 Aspect Ratio 76 Table 14.13 Edge Finish 77 Table 14.14 Edge of Glass to Edge of Hole 77 Table 14.15
21、Designed InterferenceMolding 78 Table 14.16 Windshield Installation Angle 78 Table 14.17 Windshield Deflection . 78 Table 14.18 UV Transmission 78 Table 14.19 Light Transmission (AS) Requirements 79 Table 14.20 Infrared Glass 79 Table 14.21 Heated Glass . 79 Table 14.22 Urethane Bead Height . 80 Tab
22、le 14.23 MoldingsFixed Glass . 80 ix Table of ContentsTable 14.24 Molding Criteria . 81 Table 14.25 SealsVent Window 81 Table 14.26 GasketsWindshield 81 Table 14.27 Glass SupportWindshield . 82 Table 14.28 Glass Support Fixed Position . 82 Table 14.29 Wiper QualityInterface Control Document 82 Table
23、 14.30 Wiper QualityInterface 83 Table 14.31 Wiper Zones Single Pane . 83 Table 14.32 Wiper Zones Multiple Panes 83 Table 14.33 Joint Movement 84 Table 14.34 Encapsulated Glass Capabilities 84 Table 14.35 Thermal Shock 84 Table 14.36 Optical Considerations 85 Table 14.37 Glass Curvature 85 Table 14.
24、38 Glass Edge Grind #1. 85 Table 14.39 Glass Edge Grind #286 Table 14.40 Glass Edge Grind #3. 86 Table 14.41 Glass Edge Grind #4. 87 Table 14.42 Heated Windscreens 87 Table 14.43 Product Validation for Wired Parts 88 Table 14.44 Antennas 88 Table 14.45 AS Designations . 89 Table 14.46 Glass Toleranc
25、e . 89 Table 14.47 Regulatory Requirements . 90 Table 14.48 Technical Properties of Glass 90 Table 14.49 Technical Properties of Polyvinyl Butyral 91 Table 14.50 Tempered Glass Criteria 91 Table 14.51 Extrusions 91 Table 14.52 Seals 92 Table 14.53 Primer Path 92 Table 14.54 Laminated Sidelites 92 Ta
26、ble 14.55 Photovoltaic Glass 93 Table 14.56 Seal ConstructionHorizontal Seals 93 Table 14.57 Seal ConstructionY Seals . 94 Table 14.58 Seal ConstructionCoating Areas 94 Table 14.59 Locating Pins . 94 Table 14.60 Datums . 95 Table 14.61 Field FailureDelamination 95 Table 14.62 Field FailureFogging 95
27、 x Table of ContentsTable 14.63 Material Storage 96 Table 14.64 Windshield Forming Capability . 96 Table 14.65 Polycarbonate Glazing. 96 Table 14.66 Banded Glass . 97 Table 14.67 Windshield Installation Tooling . 97 Table 14.68 Manually Applied Windshield Installation 98 Table 14.69 Windshield Racki
28、ng . 98 Table 14.70 Seal DeflectionDoor Systems 98 Table 14.71 Lamination Inspection GuidelinesAntenna . 99 Table 14.72 Lamination Inspection GuidelinesGlass Form 99 Table 14.73 Lamination Inspection GuidelinesEdge Quality . 100 Table 14.74 Lamination Inspection GuidelinesInside Contamination 101 Ta
29、ble 14.75 Lamination Inspection GuidelinesOther Visual Defects 101 Table 14.76 Lamination Inspection GuidelinesFrit 102 Table 14.77 EncapsulationMold Release . 103 Table 14.78 Frit and Primer Dimensions . 103 Table 14.79 Rate of Change in Drop Glass 104 Table 14.80 Glass Deflection upon Installation
30、 . 104 Chapter 15 - Design and Processing Criteria 105 15.1 Global Comparison: Laminated Windscreens . 105 15.2 Global Comparison: Toughened Bodyglass . 106 15.3 Windshield Design Technical Assumptions . 108 15.4 Laminate Windshield Inspection Notes . 108 15.5 Typical Product Flow from Point of Prod
31、uction to Assembly 109 Index . 111 About the Author .117 xi Table of ContentsForeword In 2010, a group of body engineers began working on a concept vehicle to replace the existing bus that had been in service for about forty years. We would joke that a bus is simply a collection of glass; seats; ply
32、wood floors; and federal, state, and local regulations. We had a team that understood plywood flooring, metal fabrication, and, of course, all the regulations. We really needed help with glass. In our search we started to utilize suppliers to aid in the creation of glass surfaces, but we didnt under
33、stand the position we were painting ourselves into. In our search for additional resources to meet the project timeline we ran into Lyn Zbinden. Lyn had previous experience with glass from his years at General Motors, and was quick to explain how we had driven the cost of our windshield up by increa
34、sing the chord length of the glass to where it would not fit into a high-volume glass furnace. Our team had increased the glass length to avoid blind spots at the sides of the windshield. The glass suppliers were good at pointing out the need for gentle radii at the corners and a lot of other factor
35、s that made the glass look clean in its design, but had not told us that the price would increase so dramatically. After working with Lyn to understand the issue, I asked him to document his knowledge and put together a best-practice document that summarized his years of experience. I never thought
36、we had enough for even a hundred pages of material when he accepted the assignment. This journey has proven that you dont know what you dont know. We really had a limited knowledge of glass altogether. Lyn has written a wonderful summary of how glass design should be approached as well as how unders
37、tanding cost drivers and negotiation can make a successful product launch. His book has enabled him to simplify theory into a practical application useful to both new and experienced engineers. Matt Thomas PDT Leader Navistar 20082011 xiii Preface My intent in writing this book is to develop enginee
38、rs specializing in glass design (windshield, side, and backlite) for the transportation industry. The key word is “develop.” You do not have to be a glass engineer or designer; in fact, any person with some mechanical reasoning ability can be successful. Thirty years of experience has laid the groun
39、dwork for some practical and cost-effective engineering solutions. These design principles have been made design rules by corporations such as General Motors and Navistar. The results have been staggering: reduction in serial process design by over 75%, and warranty reduction that totals in the mill
40、ions. I will give some technical background just to refresh your physics, but the goal is to keep things practical. My clients hire me to get their staff up and running within six months. The key to achieving success in a program remains in knowledge and the art of compromise. Ergonomics and Aerodyn
41、amics departments (maybe managers?) support an agenda that achieves their goals. But if they are unaware of the financial constraints attached to their desired objectives, engineers may go well into the program timeline before they realize that these expectations may add more burden than what is all
42、owed for in the program budget. Another consideration relates to state and federal regulations which, if not thoroughly understood, may severely impact both timing and cost. This is a critical area of study if you happen to be building school buses. An important fact that will impact or drive design
43、 will be the mode of transportation and the associated production runs. If one is working in the heavy truck, bus, or RV field, he or she will soon learn that the opportunities for favorable pricing might just have gone out the proverbial window. Limited production reduces the economies of scale dra
44、matically, unlike the automotive industry where your production runs are based off of multiple vehicle lines and will likely be in the 150,000-vehicle range. The engineer is now faced with a dwindling supply base, unwilling to have up-front engineering work done at the suppliers expense. I have seen
45、 many great concepts go by the wayside due to volumes and capacity constraints. Another important factor, especially in glass, is logistics. When the purchasing department is looking to get their best price, as they should, unrealistic desires are placed upon the process. Transportation costs are th
46、e first thing that upper management keys in on during the program planning stage. In the glass industry, float plants are few and far between. They are costly to build and must be run continuously for years to recoup the investment to construct them. In program sourcing for a product that may be ass
47、embled in the Mid-West, I may get favorable piece pricing from a supplier in the Far East. Now the fun starts. xv The suppliers give you a price with a tremendous price delta, but are unwilling to set up a satellite facility near my assembly plant. Now you find that those great prices just evaporate
48、d, and you are back to the sourcing exploration phase. This is time that, unfortu- nately, is lost. In some large automotive companies, every minute a vehicle assembly is not operational can cost up to $26,000. What is the purpose of the windshield in a modern vehicle? Is it a weather barrier, a pro
49、jectile shield, a bug screen? In reality, a windshield is all those things and more, including a safety device. It is as important to your security while on the road as a seat belt, child seat, or even the air bag. The windshield is designed to keep occupants from being thrown from the vehicle in case of impact, to support the roof in a rollover accident, and to position the passenger-side airbag for the most effective protection. Properly bonding that windshield to the vehicles body is paramount to the safety of the occupants. When I lecture or teach, I
