Fine bubbles in the edge after the autoclave process

Film temperature too high after pressure release

Cooling stage in the autoclave process must be lengthened until max. glass temperature of 40°C (104°F) is reached, then release pressure and immediately open the door. Check the glass temperature with measuring instrument; calibrate measuring sensor/autoclave if necessary

Larger bubbles in the edge/bubbles limited locally

Poor edge seal in pre-laminate

Improve by raising temperature during pre-lamination

Film at the two longitudinal edges too wet

Store rolls at 25 – 30% rel. humidity Check climate setting in processing room prüfen

Creases in the film due to incorrect lay-up

Processing room/ personnel training

Film pulled out prior to cutting (too thin or missing)

Processing room/ personnel training

Plies not correctly placed together or poorly bent

Ensure accurate match Check bending tolerance

Inserted objects too thick/not suitable for assembly

  Check objects Increase PVB film thickness

Autoclave process not optimal (too low/too high pressure increase in comparison with temperature; pressure release when temperature is too high)

Optimise process acc. to recommendation

Supporting material is too soft

Use harder supporting materials, e.g. Teflon strips

Bubbles everywhere

Incorrect pre-laminate conditions (too high/too low deairing temperature)

Change machine settings such as radiator temperature, glass speed, etc. Lower speed, yet retain temperature

Edge sealed too quickly

Cool down (T lower, speed higher)

Autoclave process incorrect

see 1.1 and recommendations

Wrinkles in the PVB film

see 1.1

Thickness tolerances in the glass or uneven FTG/HSG

Check tolerances (straight edge, waviness detection)

Delamination patchy/localy

Insufficient adhesion

Check washing water quality Conductivity ≤ 20 µS

Too little/too much detergent in the washing water (dirt/cutting oils as residue on the glass)

Check dryness of washed glass

Check washing brush setting; renew brushes if necessary

Check film moisture/climate in the lay-up room; check glass planeness FTG/HSG with straight edge

Check bending tolerance of glass

Check coating compatibility of glass to PVB

Check pre-laminate conditions/ autoclave parameters; see 1.1

For screen printing on glass: check compatibility/ level of printing

Bubbles in Laminated Safety Glass

Wrinkles in PVB

Change processing conditions; see 1.1

Faulty glass alignment/glass bending tolerances too high

Check tolerances Optimise glass alignment

Glass temperature too high when laminated

Check washing conditions; see 1.3

Pre-laminate conditions wrong/too early edge seal/roll gap too wide

see 1.1 and 1.2

Inserted objects too thick/ not suitable

Check objects; see 1.1

Glass coating not compatible with PVB film

Check compatibility

Moisture content in PVB too high

Check climate setting/ lay-up room

Moisture in Laminated Safety Glass too high/too low

Film stored too humid/ too dry

Check storage conditions/ packaging

Climate in the lay-up room

Check climate (should be approx. 25 – 30% rel. humidity)

Washed glass is not dry

Check washing machine (washing water temperature, drier, line speed)

Storage time of pre-laminate is too long

Shorten storage time

Film wrongly stretched (windscreen)

Check stretch conditions Use PVB film with higher initial moisture

Moisture measuring instrument has not been calibrated

Check calibration/ moisture standard

Adhesion too high/ too low

Moisture content

Check PVB storage conditions. Room climate approx. 25 – 30% rel. humidity

Glass quality

Check origin of glass/coating/ glass treatment/storage conditions/Fire or tin side to the PVB (check with UV lamp)

Quality of glass washing

Check washing conditions/ degree of glass drying Washing water conductivity ≤ 20 µS, detergents?

Incorrect autoclave cycle

Check parameters, control instruments

Adhesion test (e.g. pummel temperature > -18°C/0°F)

Implementation acc. to instructions/ personnel training (Pummel test: -18°C/0°F)

Impurities on glass/on PVB

Cleanliness of lay-up room Cleanliness of glass/PVB

PVB film quality

Change film type Check with Technical Service TROSIFOL

Ball-drop test/ head form test not passed

Falling height too low/ glass adhesion too high

Carrying out the test acc. to instructions/standards. Number and thickness of the specimens Check PVB film thickness/after stretching Temperature of the glass samples incorrect (should be: 23°C/73°F)

Laminated safety glass only partly ok after production process

Uneven temperature distribution in the autoclave

Check function of autoclave (fan, display instrument, etc.)

Laminated Safety Glass autoclaved in too thick layers (inner layer too cold)

Lengthen holding time

Pressure points with thinned film/diminished colour (with colour films) due to excessive clamping pressure of the glass in the autoclave

Change packing density Check degree of clamping