Patent Application
20220148550
The described embodiments relate generally to a micro-perforated panel systems, methods for noise abatement, methods of meeting safe breaking requirements and methods of making micro-perforated panel systems. In particular, embodiments relate to glass micro-perforated panel systems for noise abatement and meeting safe breaking requirements.
Glass is a highly desirable architectural product owing to its superior optical attributes, scratch and corrosion resistance, durability, waterproof, aesthetic quality, fire resistance, etc. For example, unlike polymeric materials such as polycarbonate, glass does not “yellow” over time, has high strength and scratch resistance, and may be cleaned using UV methods. However, the high density and acoustic impedance of glass leads to high acoustic reflections (e.g., echo), poor speech intelligibility, and a low noise reduction coefficient (NRC) which limits its widespread use in architectural applications particularly. Ordinary glass has nearly no sound absorption coefficient (NRC about 0.05) leading to undesirably long reverberation time and poor acoustic environment when used.
Establishing optimal room acoustics has been a growing need for many interior architectural applications including, for example, open office workspace, hospitals, classrooms, airports, automotive applications, and more. Not only can continuous exposure to sound levels greater than 85 decibels (dB) lead to hearing loss, but even noise at much lower level can be a significant distraction and lead to reduced productivity, reduced ability to concentrate or rest, and in general make a room acoustically unpleasant. Current approaches for sound absorbing include the use of acoustic foam, fibrous materials, and other non-transparent, non-glass materials.
It is desirable that glass used in architectural applications break safely upon various types of impact. For example, it is important that the glass or glass ceramic not break into large sharp shards upon impact. Specifically, it is desirable that the glass meet safe breaking requirements outlined in ANSI Z97.1, including that upon testing, e.g. hole punch impact testing, the total of the 10 largest crack-free pieces weighs no more than the weight of 10 square inches of the original test sample and no one piece is longer than 4 inches with minor exceptions.
A technical solution is required to improve acoustic properties, including NRC rating, and safe breaking properties of glass to be used in various operative environments where noise control and safe breaking is desirable.
According to an embodiment of the present technology, an article comprises a glass or glass ceramic panel having a plurality of micro-perforations positioned at non-uniform intervals along the panel wherein the panel has regions of close spacing between micro-perforations and regions of broad spacing between micro-perforations.
For example, the regions of close spacing can have a distance between micro-perforations of between about 0.25 mm and about 5 mm, or between about 1 mm and about 2 mm.
For example, the regions of broad spacing can have a distance between micro-perforations of between about 0.5 mm and about 6 mm, or between about 2 mm and about 4 mm.
For example, the ratio of the distance between micro-perforations in the regions of broad spacing to the distance between micro-perforations in the regions of close spacing is between about 1.3 and about 12, or between about 1.8 and about 4.
In some embodiments, the thickness is between about 0.5 mm and about 4 mm, or between about 0.7 mm and about 1.2 mm.
In some embodiments, the panel can comprise a strengthened glass or glass ceramic, e.g., mechanically, thermally or chemically strengthened.
In some embodiments, the panel can have a Noise Reduction Coefficient (NRC) of between about 0.3 and 1, or between about 0.3 and about 0.8.
In some embodiments the panel has a predetermined sound absorption coefficient over a predetermined frequency band between 250 Hz and 6000 Hz, or between 250 Hz and 20,000 Hz.
In some embodiments, the panel breaks upon hole punch impact to produce crack-free pieces and wherein the weight of the ten largest crack-free pieces is less than or equal to the weight of 10 square inches of the original panel.
In some embodiments, the micro-perforations are distributed with non-uniform density along the panel.
In some embodiments, an opening of a plurality of the micro-perforations are non-circular.
In some embodiments, the porosity of micro-perforations is in the range of about 0.05% to 10%.
In some embodiments, the diameter of each of the plurality of micro-perforations is between about 20 um and about 700 um, or between about 200 um and about 500 um.
In another embodiment of the technology, an article comprise first and second glass or glass ceramic panels each having a plurality of micro-perforations positioned at non-uniform intervals along the panel wherein the panels each have regions of close spacing between micro-perforations and regions of broad spacing between micro-perforations.
In some embodiments, the first and second panels are spaced from each other by an intra-panel gap that defines a separation distance.
In some embodiments, the first and second panels are generally parallel to each other.
In some embodiments, the article is thermally strengthened.
In some embodiments, the first and second panels are positioned such that there is no solid back wall within 1 m of the first and second panels that is generally parallel to the first panel or the second panel.
In some embodiments, the first and second panels are positioned such that there is a solid back wall within 1 m of the first and second panels that is generally parallel to the first panel or the second panel.
In some embodiments, the NRC of the article is 0.4 or greater.
In some embodiments, the porosity of micro-perforations in each of the first and second glass or glass ceramic panels is in the range of about 0.05% to about 10%.
In some embodiments, the diameter of each of the plurality of micro-perforations is in the range of about 50 um to about 700 um, or about 200 um to about 500 um.
In another embodiment of the present technology, a method of forming micro-perforations in a glass or glass ceramic panel comprises forming a plurality of damage tracks into the glass or glass ceramic panel by a laser beam, wherein the damage tracks are positioned at non-uniform intervals with regions of close spacing between damage tracks and regions of broad spacing between damage tracks; and etching the panel obtained from (i) in an acid solution to form a micro-perforated panel with micro-perforations at non-uniform intervals along the panel having regions of close spacing between micro-perforations and regions of broad spacing between micro-perforations, wherein the NRC of the micro-perforated panel is between about 0.3 and 1 and the glass or ceramic panel meets ANSI Z97.1 breaking requirements.
In some embodiments, the laser beam is a pulsed laser beam having a focal line oriented along a beam propagation direction and directing the laser beam focal line into the panel.
In some embodiments the method also involves etching the glass panel in a second acid solution that is different from the first acid solution.
In some embodiments, the method also involves chemically or thermally strengthening the micro-perforated panel.
In some embodiments, the glass or glass ceramic panel comprises a high-strength glass or glass ceramic composition.
In some embodiments, the thickness of the glass or glass ceramic panel is between about 0.5 mm and about 4 mm, or about 0.7 mm and about 1.2 mm.
Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description and claims hereof, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are merely exemplary, and are intended to provide an overview or framework to understand the nature and character of the claims.
The accompanying figures, which are incorporated herein, form part of the specification and illustrate embodiments of the present disclosure. Together with the description, the figures further serve to explain the principles of and to enable a person skilled in the relevant art(s) to make and use the disclosed embodiments. These figures are intended to be illustrative, not limiting. Although the disclosure is generally described in the context of these embodiments, it should be understood that it is not intended to limit the scope of the disclosure to these particular embodiments. In the drawings, like reference numbers indicate identical or functionally similar elements.
In the following detailed description, numerous specific details may be set forth in order to provide a thorough understanding of embodiments of the invention. However, it will be clear to one skilled in the art when embodiments of the invention may be practiced without some or all of these specific details. In other instances, well-known features or processes may not be described in detail so as not to unnecessarily obscure the invention. Moreover, unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In case of conflict, the present specification, including the definitions herein, will control.
Although other methods and can be used in the practice or testing of the invention, certain suitable methods and materials are described herein.
Disclosed are materials, compounds, compositions, and components that can be used for, can be used in conjunction with, can be used in preparation for, or are embodiments of the disclosed method and compositions. These and other materials are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these materials are disclosed that while specific reference of each various individual and collective combinations and permutation of these compounds may not be explicitly disclosed, each is specifically contemplated and described herein.
As used herein, the term “about” means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. In general, an amount, size, formulation, parameter or other quantity or characteristic is “about” or “approximate” whether or not expressly stated to be such. As used herein, “approximately” or “about” may be taken to mean within 10% of the recited value, inclusive.
The term “or”, as used herein, is inclusive; more specifically, the phrase “A or B” means “A, B, or both A and B.” Exclusive “or” is designated herein by terms such as “either A or B” and “one of A or B,” for example.
The indefinite articles “a” and “an” are employed to describe elements and components of the invention. The use of these articles means that one or at least one of these elements or components is present. Although these articles are conventionally employed to signify that the modified noun is a singular noun, as used herein the articles “a” and “an” also include the plural, unless otherwise stated in specific instances. Similarly, the definite article “the”, as used herein, also signifies that the modified noun may be singular or plural, again unless otherwise stated in specific instances.
As used herein, ranges are inclusive of the end points, and “from,” “between,” “to,” “and,” as well as other associated language includes the end points of the ranges.
As used herein, the term “micro-perforations” may include circular and/or non-circular shaped micro-holes. The term “non-circular” may include any arbitrary shape that is not circular. The term “diameter” may be taken to mean the minimum distance across an opening of the micro-perforation at a point through the centroid of the micro-perforation, where the centroid and diameter are based on the area of the micro-perforation on a surface of the panel in which the micro-perforation is present. For example, when the micro-perforations are substantially circularly cylindrical, the diameter is the distance across the center of the circle defining the opening.
Additionally, as shown in
Addressing room acoustics is challenging as it involves both architectural design and engineering in addition to acoustic science and principles. Micro-perforated panels in general may form a resonant sound absorbing system, based on the Helmholtz resonance principle.
There can be safety concerns with architectural uses of glass or glass ceramic materials. For example, the glass or glass ceramic panels may break into large shards if damaged. As such, glass and glass ceramic materials for use in architecture must meet the ANSI Z97.1 standard for safe breaking. The present disclosure offers glass and glass ceramic panels that have acoustic benefits while also having features that allow them to break safely and meet the ANSI Z97.1 breaking standard, e.g. for use in architectural applications.
As shown in
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As shown in
In some embodiments, the ratio of the distance between micro-perforations in the regions of broad spacing to the distance between micro-perforations in the regions of close spacing is between about 1.3 to about 12, about 1.5 to about 12, about 2 to about 12, about 4 to about 12, about 6 to about 12, about 8 to about 12, about 10 to about 12, about 1.3 to about 10, about 1.5 to about 10, about 2 to about 10, about 4 to about 10, about 6 to about 10, about 8 to about 10, about 1.3 to about 8, about 1.5 to about 8, about 2 to about 8, about 4 to about 8, about 6 to about 8, about 1.3 to about 6, about 1.5 to about 6, about 2 to about 6, about 4 to about 6, about 1.3 to about 4, about 1.5 to about 4, about 2 to about 4, about 1.3 to about 2, about 1.5 to about 2 or about 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 3.0, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 23, 24 or any range having any two of these values as endpoints. In some embodiments, the distance between micro-perforations in the regions of broad spacing to the distance between micro-perforations in the regions of close spacing is between about 1.3 and about 24, or about 1.3 and about 12, or about 1.8 and about 4. In one embodiment, the ratio of the distance between micro-perforations in the regions of broad spacing to the distance between micro-perforations in the regions of close spacing is about 2.
In some embodiments, the thickness of the glass panel is between about 0.5 mm and about 1 mm, about 0.5 mm and about 1.5 mm, about 0.5 mm and about 2 mm, about 0.5 mm and about 2.5 mm, about 0.5 mm and about 3 mm, about 0.5 and about 3.5 mm, about 0.5 and about 4 mm, about 1 mm and about 2 mm, about 1 mm and about 2.5 mm, about 1 and about 3 mm, about 1 and about 3.5 mm, about 1 mm and about 4 mm, about 2 mm and about 3 mm, about 2 mm and about 3.5 mm, about 2 mm and about 4 mm, about 2.5 mm and about 3 mm, about 2.5 mm and about 3.5 mm about 2.5 mm and about 4 mm, about 3 mm and about 4 mm. In some embodiments, the thickness may be about 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2.0 mm, 2.1 mm, 2.2 mm, 2.3 mm, 2.4 mm, 2.5 mm, 2.6 mm, 2.7 mm, 2.8 mm, 2.9 mm, 3.0 mm, 3.1 mm, 3.2 mm, 3.3 mm, 3.4 mm, 3.5 mm, 3.6 mm, 3.7 mm, 3.8 mm, 3.9 mm, 4.0 mm, or any range having any two of these values as endpoints. In some embodiments the thickness of the glass panel is between about 0.5 mm and about 4 mm, or between about 0.7 mm and about 1.2 mm.
In some embodiments the diameter of the micro-perforations is about 50 um to about 100 um, about 50 um to about 200 um, about 50 um to about 300 um, about 50 um to about 400 um, about 50 um to about 500 um, about 50 um to about 600 um about 50 um to about 700 um, about 100 um to about 200 um, about 100 um to about 300 um, about 100 um to about 400 um, about 100 um to about 500 um, about 100 um to about 600 um, about 100 um to about 700 um, about 200 um to about 300 um, about 200 um to about 400 um, about 200 um to about 500 um, about 200 um to about 600 um, about 200 um to about 700 um, about 300 um to about 400 um, about 300 um to about 500 um, about 300 um to about 600 um, about 300 um to about 700 um, about 400 um to about 500 um, about 400 um to about 600 um, about 400 um to about 700 um, about 500 um to about 600 um, about 600 um to about 700 um, about 600 um to about 700 um. In some embodiments, the diameter of the micro-perforations may be about 50 um, 100 um, 150 um, 200 um, 250 um, 300 um, 350 um, 400 um, 450 um, 500 um, 550 um, 600 um, 650 um, 700 um, or any range having any two of these values as endpoints. In some embodiments, the diameter of the micro-perforations is between about 50 um and about 700 um, or between about 200 um to about 500 um.
In some embodiments, the micro-perforations are distributed with non-uniform density.
In some embodiments, the porosity of micro-perforations in the glass or glass ceramic panel is in the range of 0.05% and up to 10%. “Porosity” is the area of the micro-perforations divided by the surface area of a surface of the glass or glass ceramic panel (including the porosity area) in which the micro-perforations are formed. Where the pores have a non-uniform cross section, the area at the surface of the glass or glass ceramic panel is used to calculate porosity. Where a pore is present, the porosity will be greater than zero, but may be quite low. In some embodiments, the porosity may be 0.05%, 0.1%, 0.2%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, or any range having any two of these values as endpoints. Porosity values outside the range 0.05%-10% may be used in some situations.
In some embodiments the micro-perforations can be in a grid-like configuration, e.g. based on squares and perpendicular lines, as shown in
Without wishing to be bound by theory, Applicants previously determined that micro-perforations in glass and glass ceramic panels produce desirable acoustic properties for architectural uses. This is discussed in Applicant's co-owned WO 2018/085249A1 and WO 2018/200760A1, the contents of which are incorporated herein in their entirety. However, Applicants determined that glass and glass ceramic panels without micro-perforations provide more desirable safe breaking characteristics. Specifically, Applicants noted that the micro-perforations change the frangible breaking pattern of the glass or glass ceramic panel without micro-perforations (as shown in
For example,
As another example,
An NRC value of 1 is the highest value and those greater than approximately 0.3 are desirable for architectural applications, preferably greater than approximately 0.4.
In some embodiments, the panel is configured to decrease reverberation time of an operative environment. As used herein, “operative environment” may include an enclosed or semi-enclosed environment that requires a certain acoustic environment. For example, conference rooms, offices, schools, hospitals, manufacturing facilities, clean rooms (food, pharmaceutical), museums, historical buildings, restaurants, etc., may all be “operative environments”. In some embodiments, the panel is integrated in a lighting solution, for example, a lighting fixture in a ceiling or a wall. In this regard, the transparent nature of the panel is used to allow for light, while taking advantage of the noise reduction properties of the panel. Natural air spacing behind the panel (in the lighting fixture) may also be advantageous from a noise reduction perspective.
In some embodiments, the panel includes a strengthened glass or glass ceramic. The use of glass or glass ceramic materials allows for favorable properties, including any one of or a combination of providing a transparent, translucent or opaque appearance, providing durability, providing resistance to corrosion, providing design flexibility, and providing flame resistance.
In some embodiments, for a strengthened glass, the surface compression is balanced by a tensile stress region in the interior of the glass. Surface compressive stress (“CS”) greater than 400 MPa, greater than 500 MPa, greater than 600 MPa, greater than 700 MPa, or greater than 750 MPa and compressive stress layer depths (also called depth of compression, or “DOC”) greater than 40 microns are readily achieved in some glasses, for example, alkali aluminosilicate glasses, by chemically strengthening processes (e.g., by ion exchange processes). DOC represents the depth at which the stress changes from compressive to tensile.
In some embodiments, the panel includes a non-strengthened glass, for example, a soda-lime glass. In some embodiments, the panel includes strengthened glass or glass ceramic that is mechanically, thermally or chemically strengthened. In some embodiments, the strengthened glass or glass ceramic may be mechanically and thermally strengthened, mechanically and chemically strengthened or thermally and chemically strengthened. A mechanically-strengthened glass or glass ceramic may include a compressive stress layer (and corresponding tensile stress region) generated by a mismatch of the coefficient of thermal expansion between portions of the glass or glass ceramic. A chemically-strengthened glass or glass ceramic may include a compressive stress layer (and corresponding tensile stress region generated by an ion exchange process). In such chemically strengthened glass and glass ceramics, the replacement of smaller ions by larger ions at a temperature below that at which the glass network can relax produces a distribution of ions across the surface of the glass that results in a stress profile. The larger volume of the incoming ion produces a CS on the surface portion of the substrate and tension in the center of the glass or glass ceramic. In thermally-strengthened glass or glass ceramics, the CS region is formed by heating the glass or glass ceramic to an elevated temperature above the glass transition temperature, near the glass softening point, and then cooling the surface regions more rapidly than the inner regions of the glass or glass ceramic. The differential cooling rates between the surface regions and the inner regions generates a residual surface CS, which in turn generates a corresponding tensile stress in the center region. In one or more embodiments, the glass substrates exclude annealed or heat strengthened soda lime glass. In one or more embodiments, the glass substrates include annealed or heat strengthened soda lime glass
Applicants also unexpectedly determined that the time required to chemically strengthen glass panels with a mixed pitch pattern of micro-perforations incorporating both closely spaced and broadly spaced micro-perforations (e.g., ˜1.5 mm for close spacing and ˜3.0 mm for broad spacing) is lower than the time required to chemically strengthen glass panels with micro-perforations with uniform spacing that do not incorporate the mixed pitch (e.g., 2.0 mm spacing). In one specific example, the time required to chemically strength glass panels with a mixed pitch pattern of micro-perforations incorporating both closely spaced and broadly spaced micro-perforations with ˜1.5 mm for close spacing and ˜3.0 mm for broad spacing took approximately 6 hours. In one specific comparative example, the time required to chemically strengthen glass panels with micro-perforations with uniform spacing that do not incorporate the mixed pitch with 2.0 mm spacing took approximately 10 hours. Hence by using this mixed pitch spacing, it is possible to not only achieve the acoustic benefits, safe breaking benefits and also lower the chemical strengthening time. This in turn would also reduce the process cost associated with chemical strengthening.
In some embodiments, the glass or glass ceramic may have surface compressive stress of between about 100 MPa and about 1000 MPa, between about 100 MPa and about 800 MPa, between about 100 MPa and about 500 MPa, between about 100 MPa and about 300 MPa, or between about 100 MPa and about 150 MPa. In some embodiments, the DOC may be between 0.05*t and about 0.21*t (where t is thickness of the glass or glass ceramic in micrometers). In some embodiments, DOC may be in the range from about 0.05*t to about 0.2*t, from about 0.05*t to about 0.18*t, from about 0.05*t to about 0.16*t, from about 0.05*t to about 0.15% from about 0.05*t to about 0.12*t, from about 0.05*t to about 0.1*t, from about 0.075*t to about 0.21*t, from about 0.1*t to about 0.21*t, from about 0.12*t to about 0.21*t, from about 0.15*t to about 0.21*t, from about 0.18*t to about 0.21*t, or from about 0.1*t to about 0.18*t.
In some embodiments, the panel has an NRC of between about 0.3 and 1, or between about 0.3 and 0.8. In some embodiments, the panel has a predetermined sound absorption coefficient over a predetermined frequency band between 250 Hz and 6000 Hz, or between 250 Hz and 20,000 Hz. In some embodiments, the panel may be “tuned” to absorb particular frequencies of interest, for example, in a machinery room or for a HVAC application. In some embodiments, the panel has an NRC of 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, or any range having any two of these values as endpoints.
In some embodiments, the panel of present disclosure includes a coating, such as a photochromic, thermal control, electro-chromic, low emissivity, UV coatings, anti-glare, hydrophilic, hydrophobic, anti-smudge, anti-fingerprint, anti-scratch, anti-reflective, ink jet decorated, screen-printed, anti-splinter, etc. In some embodiments, the micro-perforations are not blocked by the coating. In some embodiments, the interior of the micro-perforations are not coated. In some embodiments, a portion of the micro-perforations are blocked by the coating. In some embodiments, the panel includes an anti-microbial component.
In some embodiments, the panel of present disclosure may be of uniform thickness, or non-uniform thickness. In some embodiments, the panel may be substantially planar. In some embodiments, the panel may be curved, for example, or have a complex shape. In some embodiments, the panel may be a shape, for example, rectangular, round, etc. In some embodiments, the panel may be flexible. In some embodiments, the panel may be substantially rigid. In some embodiments, the geometric attributes of the panel (e.g., micro-perforation diameter, micro-perforation shape, pitch, panel thickness, etc.) and the absorption coefficient of the panel may be tuned to achieve desired room acoustics.
As shown in 2B, the cross section of the micro-perforations may vary along a length of the micro-perforation through the panel. For example,
In some embodiments, the micro-perforations have a generally circular cross-section through the thickness of the panel. In some embodiments, the micro-perforations have a non-circular cross-section through the thickness of the panel. For example, Applicants determined that the surface micro-perforation profile can be modified to further increase the stress concentration around the micro-perforations in order to favor the crack to propagate towards the region with higher stress concentration and help with crack arresting/termination.
In some embodiments, the articles of present disclosure may include multiple panels (e.g., double leaf or multi-leaf configurations). For example, in some embodiments, an article includes a first and second glass or glass ceramic panels, each having a plurality of micro-perforations positioned at non-uniform intervals along the panel wherein the panels each have regions of close spacing between micro-perforations and regions of broad spacing between micro-perforations. In some embodiments, the first and second panels are generally parallel to each other. In some embodiments, the panels may be spaced with a varying distance from one another, for example, non-parallel spacing, or through variation in dimensions of the panels themselves. In some embodiments, at least a portion of an edge of at least one of the panels is sealed to a holding portion. In some embodiments, one or more panels may have a sealed edge, or none may be sealed. In some embodiments, additional panels may be used, for example with uniform dimensions or varying dimensions. In some embodiments, the multiple panels may be uniformly spaced from one another, or have varying spacing. In one or more embodiments, the first and second glass or glass ceramic panels have the same thickness or a thickness that differ from one another.
In some embodiments, the intra-panel gap distance may be varied according to acoustic requirements and part of the overall design to absorb specific frequencies. In some embodiments, the intra-panel gap may be varied according to the aspect ratio, micro-perforation size, pitch, panel thickness, and the frequency range of interest, for example. In some embodiments, additional panels may be included, with multiple intra-panel gaps such that the system broadens the absorption spectra (in frequency), for example, or increases the absorption magnitude.
Some embodiments of present disclosure are directed to a method of forming micro-perforations in a glass or glass ceramic panel, including: (i) forming a plurality of damage tracks into the glass or glass ceramic panel by a laser beam, wherein the damage tracks are positioned at non-uniform intervals with regions of close spacing between damage tracks and regions of broad spacing between damage tracks; and (ii) etching the panel obtained from (i) in an acid solution to form a micro-perforated panel with micro-perforations at non-uniform intervals along the panel having regions of close spacing between micro-perforations and regions of broad spacing between micro-perforations, wherein the NRC of the micro-perforated panel is between about 0.3 and 1, or between about 0.3 and 0.8.
In some embodiments, the laser beam is a pulsed laser beam having a focal line oriented along a beam propagation direction and directing the laser beam focal line into the panel. In some embodiments, the method further includes, etching the glass panel in a second acid solution that is different from the first acid solution. In some embodiments, the method further includes, chemically or thermally strengthening the micro-perforated panel. In some embodiments, the glass or glass ceramic panel comprises a high-strength glass or glass ceramic composition. In some embodiments, the thickness of the glass or glass ceramic panel is between about 0.5 mm and 4 mm. Applicant's co-owned WO 2018/085249 includes further discussion of methods of making acoustic glass and glass ceramics with micro-perforations and is incorporated herein in its entirety.
In one example, the micro-perforations in the glass are made by scribing an array of laser damage tracks across the thickness of the glass. This method creates a single damage track through the thickness of the glass part. It uses a short pulse, e.g. ˜10 psec, laser with line focus optics to create long laser damage tracks. These tracks have a very small diameter, generally between 0.25 to 1 um. Each laser pulse creates a track that extends across the thickness of the glass. The pattern of the damage tracks, e.g. squares, allows for a method of fabrication in which the stages on the laser tool continuously move at high speed in a specific direction and the laser opens only at pre-defined locations. This happens without deacelaration or stopping the staged movement. For this design, the laser is programmed to create a damage track at close and broadly spaced intervals, e.g. 1.5 mm & 3 mm or the other distances discussed above. The region of glass within the as formed squares will drop when etched creating a thru hole in the glass.
Samples can then be preheated and immersed into a molten bath of 100% Technical grade Potassium Nitrate salt with 0.5% silicic acid. Samples remain in the bath for an allotted time. They can then be removed to drip dry and slowly cool. Once cool, the samples can be immersed or rinsed in tap water to remove excess salt crystals. Finally, the samples are rinsed with deionized water and then air dried. Alternately, other mixed salt baths can be employed at different percentages.
It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Thus, it is intended that the specification cover the modifications and variations of the various embodiments described herein provided such modification and variations come within the scope of the appended claims and their equivalents.
This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Application No. 62/813,745, filed Mar. 4, 2019, the content of which is incorporated herein by reference in its entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2020/020861 | 3/4/2020 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62813745 | Mar 2019 | US |
