Autoclave-Free Glass Laminating Machine: Portable Solution for On-Site Lamination

In glass processing, traditional autoclave-based laminating machines have long been the industry standard equipment for bonding multi-layer glass and interlayer materials such as PVB or SGP. Such machines have, however, severe limitations, especially in field applications. They are large, energy-hungry and need to be fixedly installed, which renders them unable to meet the demands of flexibility and mobility. Autoclave-free glass laminating machines represent a mobile solution that is revolutionizing field glass lamination. Here, the article explores the characteristics, operational principles and varied uses of this innovative equipment, highlighting its benefits in addressing the increasing need for field lamination.​

Breaking Through the Limitations of Traditional Autoclaves​

Traditional autoclave laminators apply high pressure and temperature to bond the glass layer strongly to the laminator. Although effective, they are large in size, occupying the entire factory room, and have complex installation and maintenance procedures. Lamination energy consumption is also high, and this results in high operating expenses. Apart from that, once they are fitted, they can no longer be shifted, making it not possible to perform lamination operations on site, for instance, building curtain wall repairs or emergency glass repairs on ships.​

The autoclave free glass laminating machine addresses these issues head-on. By eliminating the large autoclave, it significantly reduces the size and weight of the equipment overall. The equipment is modular and can be disassembled into small units weighing less than 50 kg. Portability ensures that it is easy for technicians to transport the equipment to the construction site, which may be a trip-up tower building under construction or a ship docked in the harbor.​

Innovative Design and Working Principle​

The autoclave free glass lamination machine uses alternative technology to achieve high-quality outputs in lamination without using high temperatures and pressures. Its primary feature is the vacuum-assisted bonding system. The system creates a vacuum seal around the glass and the lamination parts, eliminating all air bubbles and creating an immaculate fit between layers. By applying uniform pressure through vacuum, the machine can achieve a bond strength comparable to that of autoclave-treated glass.​

In addition to the vacuum system, the autoclave free glass lamination machine is also equipped with a cutting-edge heating unit. In contrast to the high-temperature environment inside the autoclave, it utilizes precise low-temperature heating elements to cure the interlayer material. The heating elements are positioned where they will dissipate the heat evenly over the surface of the glass and not produce hot spots that can damage the glass or interlayer. Vacuum pressure along with heat under control cuts down the process time between layers, which is typically 50% quicker than with traditional autoclave methods.​

Another important aspect of the autoclave free glass lamination machine is the easy-to-use interface. Simple control keys and digital display enable technicians to easily set the parameters for every lamination operation, including the vacuum level, heat temperature, and curing time. The equipment also has sensors integrated into it to monitor the working process in real-time, and will sound an alarm if the parameters deviate from the set values, ensuring stable high-quality products to be delivered every time.​

Diverse On-site Application Scenarios​

Building Curtain Wall Repair​

During the construction of curtain walls, laminated glass is widely used in the industry for safety and aesthetic reasons. The glass panels can, nevertheless, be damaged by accidents, weather or deterioration. Traditional methods require the removal of the damaged glass and sent to the factory for lamination, a process that takes time and money. The non autoclave laminated glass machine enables the technician to perform repair work on-site. They can quickly bond new interlayers to shattered glass or replace entire panels in the field, keeping downtime to a minimum and reducing the effect on occupants in the building.​

Marine and Offshore Applications​

Vessels employ laminated glass for their windows, windshields and observation decks in the shipping industry. In case of breakage or to upgrade, the non autoclave laminated glass machine is an easy solution. As vessels may not always be able to return to a pier that has glass laminating facilities, the portable machine can be brought aboard. It allows for immediate repair or replacement of glass components, ensuring the safety and uptime of the vessel without major delays.​

Emergency Glass Replacement​

In a natural calamity or emergency condition (e.g., earthquake, hurricane), the need for immediate replacement of glass increases manifolds. The non autoclave laminated glass machine can then be quickly deployed in the affected area. It can perform on-site glass lamination works for emergency shelters, hospitals, and other critical infrastructure, providing much-needed protection and functionality on time.

Actual Success Story​

In one recent project in a large city, a high-rise office building's curtain wall glass was broken. Using a non autoclave laminated glass machine, the repair team did on-site lamination of the damaged glass panels within a day. Not only did this save the building owner money for transporting large glass panels, but it reduced downtime for the building’s tenants, allowing them to quickly return to business as usual.​

In the marine sector, a cruise ship had several large viewing windows damaged during a storm. Instead of diverting the ship to a specialized repair dock, a team with a non autoclave laminated glass machine came directly to the ship. All of the broken windows were repaired within 48 hours, and the vessel was able to set sail again on schedule, reducing financial losses for the shipping company.​

Conclusion​

Autoclave-free glass laminating machine revolutionized on-site glass laminating operations with its portability and modularity. Breaking the constraints of traditional autoclave systems, the equipment provides a more flexible, cost-effective and efficient solution for different application scenarios. In construction, marine or emergency response sectors, this innovative equipment has been extremely valuable. MERSGlass is an autoclave-free glass laminating machine supplier. If you have further questions, you are welcome to contact us.