How is a Windshield Made

A windshield is one of the most integral components of vehicle safety - it supports the roof structure and shields passengers from oncoming precipitation, wind and airborne objects. With such an important purpose, windshields are specially made using "float method" manufacturing and tempered heat bonding. This method helps the windshield to maximize the strength and security of the entire vehicle.

Windshield Formation

In the early 1900s, vehicle windshields began utilizing safety glass to increase driver protection. However, the glass originally used for this purpose was prone to shatter. When the vehicle made impact, shattering windshields caused more injuries than they ended up preventing. Auto makers developed a new system in the mid-1900s, which is still the product used today - laminated windshields.

Modern windshields are comprised of two laminated sheets of glass, held together in the center by a plastic coating. Laminated glass is more flexible and less likely to break after minor impact. When the glass does break, the pieces are more likely to stick to the plastic rather than scatter over drivers, reducing the chance of injury from dangerous glass fragments.

Glass Manufacturing Process

Raw materials are heated until they become liquid, then fed onto a sheet of molten metal, most commonly made of tin. The glass floats on top of the metal rather than absorbing it, spreading out and forming a flat surface identical to the metal sheet. Extremely high temperatures purge impurities from the glass as it makes its way through the float chamber on a conveyor belt. The manufactured glass then enters the lehr, a specialized furnace designed to gradually reduce the temperature of the glass. If glass is cooled too quickly, stress cracks compromise the integrity of the panel, making it more susceptible to shattering.

After the glass is fully cooled, it is ready to be cut to shape using a diamond blade. The glass sheet is placed in a curved mold designed specifically for an individual vehicle. It is heated until it bends to fit the windshield-shaped mold.

The final step of the manufacturing process is tempering, a heat-induced strengthening tactic. The windshield is quickly heated to high temperatures, then the outer surface is hit with cool, high-pressure air. This technique is known as quenching, and it compresses the windshield surface. Compressed glass can withstand a much harder impact, and when it does shatter, it breaks into small, harmless, non-jagged pieces. To complete the finished windshield product, two glass panels are bonded on either side of a plastic sheet using both heat and pressure in a specialized oven known as an autoclave.

Replacing Windshields

It is not possible to replace a windshield with another from a different model vehicle, even if the manufacturer is the same. The size of the glass is incredibly precise in order to fit cleanly within the vehicle frame. Every windshield has a different curve, width and height. It is critical to adhere to the manufacturer's specific measurements when locating a replacement windshield.

When your windshield cracks or chips, it is vital to seek immediate repair or replacement. Driving with a compromised windshield can have disastrous consequences, so ensure your windshield is completely secure.

Posted By: AZ Wakulla Glass  http://azwakullaglass.com