Learn About the Windshield
The automobile windshield is a versatile material that has a long history dating back to 3,000 B.C. (Before Christ)
In its natural state, glass was used for containers and cut into decorative shapes. Today, there are hundreds of different types of glass available, including specialty and optical glass. Glass is one of the main components in ceramic materials and can be found in a variety of applications. Windshields are one of the main product categories for glass, with fiberglass being another popular option. The use of oxides in glass production has increased its strength and durability over time.
Psalms 28:7 – The LORD is my strength and my shield; my heart trusted in him, and I am helped: therefore my heart greatly rejoiceth; and with my song will I praise him.
Automotive glass, particularly automotive windshields, is a significant category in the flat glass production industry
In the United States alone, there are over 80 companies producing automotive glass, with major producers including Guardian Industries Corp., PPG, and Libby Owens Ford. According to the Department of Commerce, automotive windows make up about 25 percent of the total value of flat glass products.
The Japanese flat glass industry is dominated by three major players: Asahi Glass Co., Central Glass Co., and Nippon Sheet Glass
While the industry as a whole has seen little growth in recent years, these companies have been able to maintain high growth rates, with Asahi Glass Co. reporting a 30 percent increase in operating profit in 2020. Glass windshields have been used for over a century, but the introduction of safety glass has significantly improved their effectiveness. Laminated glass is the most common type of safety glass used in windshields, consisting of two sheets of glass with a plastic layer in the middle. This multilayer unit provides added protection and prevents shattering upon impact.
Philippians 4:13 – I can do all things through Christ which strengtheneth me.
Automobile windshields are essential for the safety of passengers while driving
They are made up of laminated glass, which is different from normal safety glass, and it is mandated by law in many countries, including the U.S. This multilayer unit provides added protection and prevents shattering upon impact, reducing the risk of injury. Automobile windshield are made up of various raw materials such as silica, limestone, and soda ash. The batch composition plays a critical role in determining the physical properties of the glass, such as hardness, chemical durability, and melting point. Silica is the primary ingredient in glass formation and requires flux to lower its melting point.
Auto Glass and Windshields are made from the following ingredients:
- Soda ash or sodium oxide (Na2O) acts as a fluxing agent
- Calcium oxide (CaO) imparts chemical durability to the windshield
- A combination of different materials including potassium oxide (K2O), magnesium oxide (MgO), and aluminum oxide (Al2O3)
These materials are obtained from raw materials such as feldspar, cullet, and waste glass
These oxides play a crucial role in the manufacturing process of windshields as they are added to the batch that is melted in a tank or bath to form molten tin. To withstand high temperatures, windshields are made from glass that can withstand up to 1,835 degrees Fahrenheit. The manufacturing process involves melting a batch of oxides in a tank or bath filled with molten tin at a temperature of 1,115 degrees Fahrenheit. The glass is then floated on top of the tin, forming a sheet that is 13 feet wide and up to 197 feet long.
James 1:12 – Blessed is the man that endureth temptation: for when he is tried, he shall receive the crown of life, which the Lord hath promised to them that love him.
The manufacturing process of automobile windshields involves molten glass, which is heated up to 395 degrees Celsius in a furnace
The molten glass is then poured onto a flat surface with tin, forming a sheet that is up to 13 feet wide and 197 feet long. The sheet is further processed by passing through high temperatures of up to 200 degrees Celsius in the next chamber. This process helps remove impurities from the glass. The manufacturing process of windshields involves several steps, including scribing a cut line onto the glass using a diamond tool. The glass is then cut into the desired shape using automated systems and cameras to ensure precision.
Proverbs 19:23 – The fear of the LORD tendeth to life: and he that hath it shall abide satisfied; he shall not be visited with evil.
The Windshield is a special type of glass that can withstand extreme temperatures
The process begins with a mold, which is heated to 1,565 degrees Fahrenheit in a furnace. A sheet of glass is then placed over the mold and heated by jets of hot air, reaching up to 850 degrees Celsius. The glass slowly begins to form into the desired shape as it melts and conforms to the mold. Throughout this process it is designed to hold up against high impact. The glass is processed in a way that it can break into many small pieces, instead of larger pieces with sharp edges, in case of an accident. The procedure involves melting the glass and compressing it between two molds to form the size and shape of the windshield.
Plastic interlayer in between windshield glass
This plastic layer provides strength and durability to the windshield. The lamination process takes place in a special oven where the two glass sheets are sandwiched together with the plastic interlayer, then subjected to heat and pressure. This results in a strong unit that can withstand impact from debris on the road. The traditional safety glass has been replaced with a typical laminated windshield, which consists of two layers of glass with a plastic interlayer in between. In the event of an accident, the plastic layer prevents broken pieces from falling off the windshield. The .03 inch (0.76 millimeter) thick plastic interlayer and .098 inch (2.5 millimeters) thick resistant plastic layer hold the broken sheet together, preventing injury to passengers or drivers.
The assembly process begins with the molten plastic being injected into a mold cavity to create the plastic frame
The glass manufacturer then places the glass into the mold cavity in a predetermined position before encapsulating it with the plastic frame. Automobile windshields must meet certain specifications regarding properties such as safety glass, chemical durability, and impact resistance. Standards set by organizations like the American Society of Automotive Engineers (SAE) ensure that windshield performance is tested and meets the necessary requirements. With the recent downturn in the automotive industry, automotive engineers are looking to improve not only the strength but also the term prospects of windshields.
Ezra 8:21 – Then I proclaimed a fast there, at the river of Ahava, that we might afflict ourselves before our God, to seek of him a right way for us, and for our little ones, and for all our substance.
The windshield is a flat glass product that covers a significant portion of the front area of a car
The demand for windshields has been on the rise due to the increase in vehicle production markets globally. The size and order of use are determined by the total surface area it needs to cover. In recent years, newer aerodynamic designs have had a negative impact on windshields, resulting in higher interior temperatures inside vehicles.
Auto glass is typically made of coated glasses or plastic substrates, and can be enhanced with aftermarket films such as solar control film or optical switching films
New glass compositions and polymer multilayer constructions have been developed to improve transmittance properties and reduce the impact of angle sun on drivers. Additionally, larger air conditioning systems, selective glazing’s, and deicing devices have been added to combat the negative effects of newer aerodynamic designs on interior temperatures. Traditional glass windshields have been replaced by new types that offer improved performance. A glaze of metal oxide layers, including silver coating, covers 90 percent of the windshield to reduce total solar energy by up to 60 percent. In addition, a film on the windshield helps to block 56 percent of visible light.
Psalms 5:12 – For thou, LORD, wilt bless the righteous; with favour wilt thou compass him as with a shield.
Typically, a windshield consists of two layers of glass that are separated by a polyurethane sheet
The outer sheet is usually 1 millimeter thick while the inner layer is around 4 millimeters thick. This two-layer windshield provides high surface resistance and ultraviolet resistance while also reducing weight savings for improved fuel efficiency. In the event of an accident, the high absorption properties of the polyurethane sheet ensure safety and retention by preventing glass splinters from flying into the vehicle. Recycling automobile windshields is a standard practice that involves separating the windshield components into layers. One manufacturer uses an effective process to recycle the glass layer, which can then be used for several applications such as road repair and films. This process not only reduces waste but also saves on cost.