Glass/metal laminated structures and methods of manufacturing laminated structures
Laminated structures comprise a metal sheet including a first face and a second face with a thickness of from about 0.5 mm to about 2 mm extending between the first face and the second face. The laminated structure further includes a first chemically strengthened glass sheet including a thickness of less than or equal to about 1.1 mm and a first interlayer attaching the first chemically strengthened glass sheet to the first face of the metal sheet. In further examples, methods of manufacturing a laminated structure comprise the steps of laminating with a metal sheet and a first chemically strengthened glass sheet together with an interlayer.
1. A laminated structure comprising:
a metal sheet comprising stainless steel and including a first face and a second face with a thickness of from about 0.5 mm to about 2 mm extending between the first face and the second face;
a first chemically strengthened glass sheet including a thickness of less than or equal to about 1.1 mm, wherein the first chemically strengthened glass sheet comprises an acid-etched glass sheet selected from the group consisting of aluminosilicate glass and alkali-aluminoborosilicate glass; and
a first interlayer attaching the first chemically strengthened glass sheet to the first face of the metal sheet, the first interlayer comprising an ionomer and having a thickness from about 0.1 mm to about 0.89 mm,
wherein, when the laminate is placed on a 1 inch thick flexible foam support and the first chemically strengthened glass sheet is impacted with a 535 g ball, the laminate exhibits impact energy of from 4.34 Joules to 7.49 Joules.
2. The laminated structure of claim 1 , wherein the Young's modulus of the first interlayer is greater than or equal to 15 MPa.
3. The laminated structure of claim 2 , wherein the Young's modulus of the first interlayer is greater than or equal to 275 MPa.
4. The laminated structure of claim 1 , wherein the first chemically strengthened glass sheet includes a thickness of from about 0.5 mm to about 1.1 mm.
5. The laminated structure of claim 1 , further comprising:
a second chemically strengthened glass sheet including a thickness of less than or equal to about 1.1 mm; and
a second interlayer attaching the second chemically strengthened glass sheet to the second face of the metal sheet.
6. A method of manufacturing a laminated structure comprising the steps of:
(I) providing a metal sheet comprising stainless steel and including a first face and a second face with a thickness of from about 0.5 mm to about 2 mm extending between the first face and the second face;
(II) providing a first chemically strengthened glass sheet including a thickness of less than or equal to about 1.1 mm, wherein the first chemically strengthened glass is selected from the group consisting of aluminosilicate glass and alkali-aluminoborosilicate glass;
(III) acid etching the first chemically strengthened glass sheet;
(IV) attaching the chemically strengthened glass sheet to the first face of the metal sheet with a first interlayer, wherein the first interlayer comprises an ionomer and has a thickness from about 0.1 mm to 0.89 mm wherein, when the laminate is placed on a 1 inch thick flexible foam support and the first chemically strengthened glass sheet is impacted with a 535 g ball, the laminate exhibits impact energy from 4.34 Joules to 7.49 Joules.
7. The method of claim 6 , wherein step (II) provides the thickness of the chemically strengthened glass sheet within a range of from about 0.5 mm to about 1.1 mm.
8. The method of claim 6 , further comprising the steps of separating a plurality of glass sheets from a source glass sheet, and chemically strengthening at least one of the plurality of glass sheets to provide the first chemically strengthened glass sheet of step (II).
9. The method of claim 8 , wherein, prior to the step of chemically strengthening the glass sheet, further comprising the step of finishing at least one edge of the glass sheet.
10. The method of claim 6 , wherein prior to step (III), further including the step of conditioning the first interlayer to control the moisture content.
11. The method of claim 10 , wherein the step of conditioning adjusts the moisture content of the first interlayer to less than 1%.
12. The method of claim 6 , wherein step (III) includes the steps of building a stack with the interlayer placed between the chemically strengthened glass sheet and the first face of the metal sheet, placing the stack within vacuum chamber, at least partially evacuating the vacuum chamber, and heating the stack to a lamination temperature.