Production Process

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Production Process Gun Bullets Ballistic Standards
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As ASGARD, we produce bulletproof glass against all levels of danger groups.

1 - Glass Cutting Line

The production journey begins when the glasses of different thicknesses that we have determined are taken with the automatic suction cup transfer machine and given to the glass cutting machine. 
In the ASGARD glass cutting line, we cut glass plates with an automatic cutting machine according to the bulletproof glass dimensions to be produced. 
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The edges of the newly cut glass are sharp. In order to eliminate the edge sharpness, we send the glass coming out of the glass cutting line to our edge processing line with glass transport trolleys.

2 -Glass Edge Processing Line

The edge sharpness of all glass plates used in the manufacture of bulletproof glass must be removed.

We remove the sharpness of all edges of the glass with automatic machines in the edge processing line. We provide the most suitable edge processing, technically speaking, by " Chamfered Flat Grinding"  .

Bulletproof glasses made without removing the edge sharpness will cause them to deteriorate in a short time as it will not allow the application of polyurethane tape to be applied to all edges in order not to be affected by moisture or deteriorate. 
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In addition, there may be a minimum difference in the width and length dimensions of the glass plates cut on the glass cutting line.

This difference will create a size difference between the layers in the lamination process where the glasses are stacked on top of each other.

Bulletproof glasses made with the difference in size between the glass plates will cause cracks and fractures during assembly.

By eliminating the size differences in the edge processing line, we ensure that all glass layers are exactly the same size.


The glasses need to go to the lamination room very clean. We send the glass coming out of the edge processing line to our washing-drying line with glass transport trolleys.
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3 -Washing and Drying Line

We wash the glass plates that come with their edge sharpness removed with the machines in the washing and drying line with specially treated water and chemical additives, and dry them with the hot blowing method with the fans located at the top and bottom of the dryer.
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Washing and drying glasses is not a simple process. On the contrary, it is one of the important processes of bulletproof glass production. Glass surface cleaning must be in desired conditions for the lamination quality to be made with Glass and  PVB + Polyurethane  binders coming to the lamination room . The hardness of the washing water should be maximum 5 ° Fr and pH 6–8. Electrical conductivity; It should be 1 μS / cm (ion amount mg ​​/ LxConductivity Factor).

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We use water that provides ideal conditions in our production lines and industrial treatment systems.

Final washing of the glasses with demineralized water is a necessary method for the quality of the product. In the condition that the desired conditions in the water are not met, the invisible undesirable minerals adhere to the glass surface with electrical conductivity.
This situation will cause a decrease in the quality of the bonding materials (PVB or Polyurethane) adhering to the glass surface with the glass, resulting in deterioration of the product.

We send the glasses, which are washed and dried with demineralized water in our washing-drying line, to our lamination line with glass transport trolleys.

4 -Lamination Line

The glasses that come with the glass carriage after being washed under the desired conditions are taken to the practice section of the lamination room and taken to the dust-proof part. While the production continues in the main laminated part, adaptation to the humidity and temperature of the environment is ensured.
Laminating Chamber, the smallest dust etc. It is a clean room where particles are purified at the same time, microorganisms at the bacterial level, and heat and humidity balance is provided.
We provide these conditions  with Ventilation and Air Conditioning Systems  .

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As ASGARD, we make production in our production facility in a working environment that is specially designed for bulletproof glass production and provided with ventilation and air conditioning system.

  • We keep PVB and Polyurethane materials in aluminum packaging at a temperature between 8 0C-10 0C until they are used.
  • Laminated room ambient temperature is between 18 0C-20 0C,
  • Ambient humidity is between 18% and 20%. 
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The floor of our lamination room is covered with antistatic and antibacterial flooring material.

In the lamination room, even if it is completely dust-free with the ventilation system, precautions must be taken against the power of Static Energy to move the particles.
PVB and other binders used in lamination tend to be affected by Static Energy. Contact with PVB and other binders with non-antistatic work clothes or bare hands causes the binders to attract particles smaller than dust to its surface.

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Our staff working in the ASGARD lamination room produce by using antistatic work clothes, gloves, caps, masks and shoe covers.

In the lamination chamber, only the materials to be laminated are predetermined in bulletproof glass making;
  • Glass plates from production
  • PVB (Polyvinylbutural), which is the binder that allows the glass plates to stick together
  • Polycarbonate in the last layer in lamination
  • Polyurethane bonding the glasses with the polycarbonate material
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As ASGARD  , we do this on a backlit lamination table for the joining of these 4 main materials and the final cleaning control.
 
We Combine All Glass Layers With Pvb (Polyvinylbutural). 
We finish the lamination process by combining (with the joined glass layers) (3 mm thick Polycarbonate material) with the Polyurethane material.

Edge Banding

We apply a protection tape that is not affected by water and moisture on the four sides of the bulletproof glasses to be used in architectural structures whose lamination is finished.  This tape will adhere perfectly to the edges of laminated glass.  
 
In bulletproof vehicle windows, we use polyurethane or acrylic based tape as it must be resistant to high wind loads.
 
Bulletproof glasses produced without the use of protection ensure that the exposed PVB and polyurethane between the glass layers are protected from air, moisture and water.  Material such as PVB and polyurethane will begin to lose due to moisture and water.
 
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The first distortions will progress from the edges of the impermeable glass towards the inner surfaces. 
As the deterioration progresses, the bulletproof glass will begin to turn yellow and air bubbles will begin to form inside.
This means that the bulletproof feature is also impaired.

5- Asgard Heating and Press Line

We send the glasses, whose joining process is completed in the lamination room, to the Heating and Press Line.  Glass Components (Glass and Polycarbonate) + Binders (PVB and Polyurethane)

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We pass the glasses that come to the Heating Furnace and Press Line with the line connected to the lamination room, whose joining process is completed, through the heating oven and the press.
The Heat Furnace ensures that the binders become more flexible. The rollers that press strongly ensure that the air in the binders comes out and adheres to the glass components.
 
• Heating Furnace and Press machine electronically measures the thickness of the laminated glass coming from the laminated chamber, and automatically adjusts it according to the thickness of the laminated glass by changing the transition time from the heat furnace, the transition speed and the furnace temperature. Likewise, it electronically determines how many bar air pressure will be printed on the cylinders in the press according to the thickness of the laminated glass.
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• Glass components passing through the heating furnace and the press and binders are adhered. The matte appearance of PVB and polyurethane binders started to become transparent with heat and press.
• Laminated glass coming out of the Heating Furnace and the Press as such, the Glass Components and Binders are not completely adhered. The air inside the PVB and polyurethane binders is not completely removed and is not completely transparent.
 
For the Heating Furnace and Press process, we can say that the autoclave that will do the real joining helped the pre-function of the process.

Vacuum Bag:

We put the Glass Components and Binders in a vacuum bag so that they adhere completely, the air inside the PVB and polyurethane binders is completely removed, and they become transparent.
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We bring the laminated glasses in the vacuum bag to the autoclave oven by placing them on the autoclave stand with the help of glass carrying suction cups attached to the crane.

6- Otaclav Oven

Autoclave oven ; It is a pressure-resistant, pressure-resistant pressure tube boiler used to bring the temperature and pressure values ​​​​to the desired limits for the process.
 
We make perfect adhesion of Glass Components and binders, PVB and polyurethane binders to become transparent by completely removing the air in the autoclave oven.

We place the laminated glasses in the vacuum bag together with the autoclave stand into the autoclave oven and close the lid.
 By taking the air molecules in the vacuum bag with the Vacuum Pump , we ensure that the laminated glass components are absorbed and combined.
 
The autoclave oven  is at a pressure of approximately 13 bar and a temperature of 135 oC.
By applying additional pressure to the glass layers that continue to combine with vacuuming, we perform a very strong, inseparable joining process.
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The process continues at different times in the autoclave, depending on the thickness of the bulletproof glass.
 
This period is approximately 6-10 hours under heat, vacuum and pressure. At the end of the time, we start to cool the inside of the autoclave by activating the cooling systems. This period is about 3-6 hours.
At the end of the process, when the laminated glass in the autoclave cools down, we open the lid and take the glasses out.
We used the term LAMINATION for the bonding process until the end of the autoclave process  and the  term  LAMINATED GLASS for  the combined semi-finished product  .
We call the product LEADPROOF GLASS , the product that has all the air bubbles in the structures of the binders, PVB and Polyurethane, expelled, and becomes a single piece as fully combined with the glasses and polycarbonate   .
We have finished our bulletproof glass production process.
 
We take 1 piece of bulletproof glass that we produce and perform a bulletproof shot test.
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We make the final physical controls and send them to the loading and shipping department.

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