Patent ID: 8097114

Claim:
A process comprising sequentially: (a) providing two rigid layers and an ionomeric interlayer, (b) constructing a sub-assembly comprising the ionomeric interlayer between the rigid layers; (c) placing the sub-assembly in a vacuum bag or vacuum press; (d) applying a vacuum to the vacuum bag or vacuum press for a maximum of 30 minutes while maintaining the sub-assembly at a temperature between 10° C. and 22° C.; (e) increasing the temperature of the sub-assembly to at least 125° C. over a minimum of 20 minutes while maintaining vacuum on the vacuum bag or vacuum press; (f) processing the sub-assembly between 125° C. and 135° C. for a minimum of 20 minutes to form a laminate having mature edge seal and to effect sufficient adhesion of all layers of the sub-assembly; (g) cooling the laminate at a rate of at least 0.5° C./minute until the laminate reaches a temperature below 40° C. to prevent the formation of edge bubbles of the laminate; and (h) removing the vacuum from the vacuum bag, containing the laminate, and allowing the laminate to reach atmospheric pressure as the laminate continues to cool to ambient temperature; wherein step (a) through step (d) are carried out at 10° C. to 22° C. and a relative humidity of greater than 0 percent but less than 40 percent; and step (d) through step (g) are carried out under a vacuum pressure of 40 kPa or less.