Solar control interlayers for laminates

Abstract

A functional interlayer for incorporation into a laminated structure is provided. The functional interlayer may provide solar control characteristics to the laminated structure. The laminated structure may be part of a window cell.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 412,102, filed on September 30, 2022, the complete disclosure of which is incorporated herein by reference for all purposes. Technical Field

[0003] The present description generally relates to laminates having functional properties (e.g., solar control properties), functional interlayers for incorporation into laminates that provide such solar control properties, and various structures including window units formed from such laminates having solar control interlayers. Background Art

[0004] Solar control films are used in windows of vehicles and residences to improve energy efficiency. In residential or commercial buildings, these solar control films help control the amount of heat gained by the sun through the windows. This helps reduce the load on heating, ventilation, and cooling systems, thereby improving energy efficiency and reducing utility costs. In cars or other vehicles, fuel efficiency can be improved by reducing the amount of heat gained through windows and sunlight. Solar control layers remove energy from sunlight while allowing visible light to pass through. Some solar control films remove energy in the infrared and / or near infrared ranges.

[0005] A laminated glass unit (LGU) is a laminated assembly that includes one or more interlayers between transparent rigid plies. The rigid plies can be glass or any other known alternatives such as polycarbonate, acrylic, polyester, and rigid transparent polyurethane. The interlayer bonds the adjacent rigid plies together to form a unitary laminated assembly and can be a thermoplastic material such as polyvinyl formal, polyvinyl butyral, polyvinyl isobutyral, silicone, or ethylene vinyl acetate (EVA).

[0006] These laminates or LGUs may include glass and / or polymer panes or layers, which provide structural strength, impact resistance, hurricane resistance, and ballistic resistance. The laminates may also include sound barriers to reduce the intrusion of automobile or building noise. Preferably, the laminates have high optical clarity, low haze, long-term thermal stability, and long-term weatherability.

[0007] Some known solar control films have a transparent flexible polymer substrate on which a thin layer of reflective metal is deposited by vapor deposition or sputtering deposition. Flexible polymer substrates are susceptible to chemical attack, mechanical wear, and lack structural support. The film is typically formed on a polyethylene terephthalate (PET) or polyethylene naphthalate (PEN) substrate. The film is incorporated into a multilayer laminate with additional layers to provide a hard protective layer, abrasion resistant coating, impact resistance, and other desired features. The film may have a pressure sensitive adhesive (PSA) coating to adhere to the glass pane, and a release liner that is then peeled off and discarded before use.

[0008] The interlayer used in the laminate must have good adhesion to the substrate as well as the rigid outer pane of the window. In addition, the interlayer must have optical clarity, durability, and suitable thermal and mechanical properties. The interlayer should have structural strength and load-bearing capacity if the rigid outer pane is damaged by criminal activity, natural disasters, weather, etc. The interlayer should accommodate the different expansion coefficients of the different layers of the laminate, have excellent optical clarity and stability, and should also have impact resistance and good adhesion.

[0009] There is a need for improved solar control interlayers that address the issues discussed above, and more specifically, there is a need for interlayers having other functional layers to reduce the need for additional layers to act as carriers or release liners, provide structural support, and / or eliminate steps in forming laminates and / or window unit subcomponents. Summary of the invention

[0010] Functional interlayers for incorporation into laminate structures are described herein that address the above-mentioned problems. The functional interlayer can provide solar control properties to the laminate structure. The laminate structure can be part of a window unit.

[0011] According to one aspect, a sandwich subassembly is provided. The sandwich subassembly may include a carrier layer and at least one thermoplastic polyurethane layer on its side. The at least one thermoplastic polyurethane layer may have adhesive properties when heated. The carrier layer may be a solar control layer. The carrier layer may be an electrochromic component, an infrared absorbing layer, or an infrared reflecting layer.

[0012] Thermoplastic polyurethane can be an optical interlayer formed by extrusion. In some embodiments, the first thermoplastic polyurethane layer is arranged on the first side of the carrier layer, and the second thermoplastic polyurethane layer is arranged on the second side of the carrier layer, and the second side is opposite to the first side. The first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer can have adhesion when heated. The first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer can have the same thickness. The first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer can have different thicknesses.

[0013] In certain embodiments, the first thermoplastic polyurethane layer, the second thermoplastic polyurethane layer, or both thermoplastic polyurethane layers may be wedge-shaped.Thus, the subassembly may form part of a head-up display (HUD) window unit.

[0014] In some embodiments, the first thermoplastic polyurethane layer can be disposed on a first side of the carrier layer, and the second layer is disposed on a second side opposite the first side. The second layer can be selected from the group consisting of polyvinyl butyral, polymethyl methacrylate, ethylene vinyl acetate, and polycarbonate. The second thermoplastic polyurethane layer can be disposed on the second layer.

[0015] In some embodiments, the first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and the layer providing acoustic damping is disposed on a second side of the carrier layer. In some embodiments, the first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and the layer providing impact resistance is disposed on a second side of the carrier layer.

[0016] In some embodiments, the first thermoplastic polyurethane layer can be disposed on the second side of the carrier layer and the photovoltaic assembly is on the first side of the carrier layer. In some embodiments, the first side can be the outward side of the window unit. The photovoltaic assembly can include a polymer layer having quantum dots. In some embodiments, the photovoltaic cells can be arranged along the edge of the carrier layer. In some embodiments, the photovoltaic cells can be disposed on one or more regions of the layer that are not relied upon to achieve transparency when the layer is in a window unit of a building.

[0017] In some embodiments, the first thermoplastic polyurethane layer can be disposed on the first side of the carrier layer, and the electrochromic component can be disposed on the second side of the carrier layer. The electrochromic component can include a transparent electrode on the second side of the carrier layer, a transparent ion-conducting polymer electrolyte membrane, and a second transparent electrode to complete the battery. An electrochromic coating can be deposited on either of the two transparent electrodes.

[0018] In some embodiments, the first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and the polyvinyl butyral layer may be disposed on a second side of the carrier layer. In some embodiments, the first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and the poly(ethylene-co-vinyl acetate) layer may be disposed on a second side of the carrier layer.

[0019] According to another aspect, a window unit for a vehicle or a building may have a sandwich subcomponent comprising a carrier layer and at least one thermoplastic polyurethane layer on its side, the at least one thermoplastic polyurethane layer being adhesive when heated, the carrier layer being a solar control layer, the sandwich subcomponent being arranged between a first rigid sheet and a second rigid sheet.

[0020] In some embodiments, at least one of the first rigid sheet and the second rigid sheet is a glass layer. In some embodiments, at least one of the first rigid sheet and the second rigid sheet is a polymer layer.

[0021] The window unit may further comprise an electromagnetic shield, a low emissivity layer, an electrochromic component and / or a photovoltaic component.

[0022] According to another aspect, a method of forming a sandwich subcomponent may be provided. The method may include providing a carrier layer and extruding a thermoplastic polyurethane layer having adhesive properties when heated on a side of the carrier layer, the carrier layer being a solar control layer.

[0023] The solar control layer may be selected from electrochromic components, infrared reflecting layers and infrared absorbing layers.

[0024] In some embodiments, a first thermoplastic polyurethane layer may be extruded on a first side of the carrier layer and a second thermoplastic polyurethane layer may be extruded on a second side of the carrier layer, the first side being opposite the second side.

[0025] A first thermoplastic polyurethane layer may be extruded onto a first surface of a carrier layer in a first pass, and then a second thermoplastic polyurethane layer may be extruded onto a second surface of the carrier layer in a second pass. The first pass and the second pass may be performed by the same extruder.

[0026] In some embodiments, the method may further include gathering the sandwich subcomponents into a roll.

[0027] In some embodiments, a first thermoplastic polyurethane layer can be extruded on a first side of the carrier layer, and a second layer can be extruded on a second side of the carrier layer, the first side being opposite to the second side, and the second layer is selected from polyvinyl butyral, polymethyl methacrylate, poly(ethylene-co-acrylic acid), alkali metal salts of poly(ethylene-co-acrylic acid), and poly(ethylene-co-vinyl acetate).

[0028] The method may further include laminating a sandwich subcomponent with the first rigid sheet and the second rigid sheet, the sandwich subcomponent being disposed between the first rigid sheet and the second rigid sheet.

[0029] In some embodiments, at least one of the first rigid sheet and the second rigid sheet may be a glass sheet.In an embodiment, at least one of the first rigid sheet and the second rigid sheet may be a polymeric rigid sheet.

[0030] In some embodiments, the first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer can be extruded simultaneously.

[0031] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and do not limit the present disclosure. Additional features of the present disclosure will be partially set forth in the following description or may be learned by practicing the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments and together with the description serve to explain certain principles.

[0033] Figure 1 is a perspective view of a solar control sandwich subassembly according to an exemplary embodiment;

[0034] Figure 2 yes Figure 1 A cross-sectional view of a sandwich sub-component;

[0035] Figure 3 is a cross-sectional view of a laminate for a window unit having a sandwich subcomponent according to an exemplary embodiment;

[0036] Figure 4 is a cross-sectional view of a sandwich sub-component according to an exemplary embodiment;

[0037] Figure 5 is a schematic diagram of an exemplary embodiment of a system for applying a coating to a first side of a solar control layer;

[0038] Figure 6 is a schematic diagram of an exemplary embodiment of a system for applying a coating to a second side of a solar control layer; and

[0039] Figure 7 is a perspective view of an exemplary embodiment of a window unit. DETAILED DESCRIPTION

[0040] This specification and the accompanying drawings illustrate exemplary embodiments and should not be considered as limiting, and claims (including equivalents) define the scope of the present disclosure. Without departing from the scope of this specification and claims (including equivalents), various mechanical, composition, structural and operational changes can be made. In some cases, well-known structures and technologies are not shown or described in detail, so as not to blur the present disclosure. Similar numbers in two or more figures represent the same or similar elements. In addition, as long as it is practicable, the elements and related aspects thereof described in detail with reference to an embodiment can be included in other embodiments that are not specifically shown or described. For example, if a certain element is described in detail with reference to an embodiment, and is not described with reference to a second embodiment, the element can still be required to be included in the second embodiment. In addition, the description herein is for illustrative purposes only, and does not necessarily reflect the actual shape, size or dimensions of the system or the components shown.

[0041] It is noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the," as well as any word used in the singular, include plural referents unless expressly and unambiguously limited to one referent. As used herein, the term "include" and its grammatical variations are intended to be non-limiting, such that recitation of items in a list does not exclude other like items that can be substituted or added to the listed items.

[0042] Described herein are sandwich subcomponents for laminating with other layers to form a laminate or laminated structure, such as a laminated glazing unit (LGU). The sandwich subcomponent may have a carrier layer, wherein one or more polymer layers are adhesive when heated. In some embodiments, the carrier layer may be a solar control layer, including a variable transmission solar control layer (e.g., an electrochromic component) or a fixed transmission solar control layer (e.g., an infrared absorbing layer or an infrared reflecting layer). The sandwich subcomponent may include a low emissivity layer, a photovoltaic component (with, for example, quantum dots), an organic photovoltaic cell or other solar concentrator (e.g., a luminescent solar concentrator (LSC)), an electromagnetic shielding layer, or other functional layer. The sandwich subcomponent may have a polymer layer on each of two opposing sides, which is adhesive when heated so that the subcomponent can be laminated with other layers. The sandwich subcomponent may be provided on a roller for lamination with other layers, the adhesive being part of the sandwich subcomponent, and the functional solar control layer being the carrier; no additional carrier is required.

[0043] In some embodiments, the sandwich subcomponent can have functional properties, such as solar control properties. Figures 1 and 2 show exemplary embodiments of such sandwich subcomponents with solar control properties. The sandwich subcomponent 10 can have a solar control layer 12 and at least one polymer layer 14 on its side. The polymer layer 14 can be a thermoplastic polyurethane (TPU), which can have adhesion when heated. Other suitable polymer materials for the polymer layer 14 can include, for example, polyvinyl formal, polyvinyl butyral (PVB), polyvinyl isobutyral, silicone and ethylene vinyl acetate (EVA). Examples of solar control layers are discussed below.

[0044] In some embodiments, the sandwich subassembly 10 can be laminated with a glass layer or an optically clear rigid polymer sheet (e.g., polycarbonate) in an autoclave to form a window unit. Other rigid polymer materials can be used, for example, acrylates, polyacrylates, polymethyl methacrylate, cellulose acetate, etc. In some embodiments, a combination of glass and polymer sheets can be used. It is contemplated that non-autoclave processes can also be used.

[0045] In some embodiments, the polymer layer 14 of TPU can be an optical interlayer formed by extrusion. Figure 1 1, the TPU layer 14 may be substantially transparent and suitable for use in a laminate of a window unit. If desired, the optional addition of polycarbonate to the TPU layer 14 may provide ballistic and impact resistance. The thickness of the TPU layer 14 may be, for example, about 15 thousandths of an inch to about 75 thousandths of an inch. In some embodiments, the polymer layer 14 may be formed using calendaring, solution casting, injection molding, and other suitable methods.

[0046] The solar control film 12 can be configured to act as a carrier itself and thereby avoid the need to use an additional carrier (such as a polyethylene terephthalate (PET) carrier) or other carriers that are subsequently peeled off and discarded before use. Figure 3 In the exemplary embodiment shown, a TPU interlayer 301 is formed on a first side of a solar control layer 300, and a TPU interlayer 302 is formed on a second side of the solar control layer 300. TPU layers 301 and 302 can be formed by a two-pass process, which will be further explained below. The interlayer subcomponents can be gathered and provided on a roll. In some embodiments, the rigid outer layers 100 and 101 can be laminated with the interlayer subcomponents to provide a laminate 305 for a window unit. Other layers can be added to provide desired functional properties, such as photovoltaic characteristics, electrochromic characteristics, impact resistance, sound insulation, structural strength, and electromagnetic shielding, etc. Layers 100 and 101 can be any glass material, rigid optically transparent polymer sheet, or a combination thereof mentioned herein.

[0047] In certain embodiments, the first thermoplastic polyurethane layer 301, the second thermoplastic polyurethane layer 302, or both thermoplastic polyurethane layers 301, 302 may be wedge-shaped. Thus, the subassembly may form part of a head-up display (HUD) window unit.

[0048] In some embodiments, the sandwich subcomponent may include invisible electromagnetic shielding and / or conductive properties, such as nanowires, sputtered electrodes, etc. Low emissivity layers, transparent conductive films, carbon nanotube transparent electrodes, and other features may be included as part of the sandwich subcomponent. The sandwich subcomponent may include photovoltaic components, electrochromic components, sound insulation layers, impact resistant layers, etc. In certain embodiments, one or more such functional layers are provided as sandwich subcomponents, and the polymer layer on each of the two opposing sides of the sandwich subcomponent has adhesion when heated.

[0049] The sandwich subassembly may include an electromagnetic interference (EMI) shield to protect wireless networks or other systems in a vehicle or building from electromagnetic interference. The EMI shielding layer may include several layers of metal that allow for significant transmission of visible light and may be provided on a polymer substrate such as PET or PEN. For example, alternating layers of dielectric or metal oxide and metal may be formed into a stack and combined with other layers in the sandwich subassembly or provided in the form of a laminate. The dielectric or metal oxide may include, for example, In 2 O 3 、TiO 2 , Nb 2 O 5 、 2 O 5 SnO 2 , ZnO or indium tin oxide (ITO). The metal can be, for example, silver, gold, copper, aluminum. In some embodiments, the subcomponent can include a stack of ITO and silver layers applied by sputter deposition or vapor deposition.

[0050] A hard coating can be combined with the sandwich sub-components disclosed herein. For example, the hard coating can be formed of epoxy resin, resin, etc. For example, the hard coating can be a cured layer of resin, such as curable silica particles. For example, a UV curable material can be used.

[0051] Exemplary embodiments of a process for forming a sandwich subcomponent may include providing a solar control film or other functional carrier layer and extruding a TPU layer on the carrier. The solar control film may be selected from an electrochromic component, an infrared absorbing layer, an infrared reflecting layer, a low emissivity ("low-e"), or other layer. In some embodiments, another TPU layer may be formed on the side of the carrier opposite to the first layer of TPU. In some embodiments, an adhesive layer of PVB or EVA may be formed on the side of the carrier opposite to the first layer of TPU. One or more layers of TPU, PVB, and / or EVA are adhesive when heated so that the sandwich subcomponent can be laminated with other layers. The solar control sandwich subcomponent may be provided on a roll and laminated into a larger component for a window unit, with the adhesive provided as a carrier on the solar control layer; no other carrier is required.

[0052] In certain embodiments, the solar control layer 300 can be a multilayer stack having electrochromic properties. The electrochromic component can include an electrochromic material having a transparent electrode formed on each opposing side. The electrochromic material is sensitive to an applied voltage. For example, transition metal oxides are used in the electrochromic material. In some embodiments, a transparent conductive layer can be provided on a layer having a tungsten oxide ("WO3") electrochromic material deposited on a PET substrate. Such electrochromic materials can be deposited by sputtering, chemical vapor deposition, and other methods. The electrochromic solar control layer or film works by adjusting the total light transmittance in the visible and infrared ranges. In this example, it is a variable transmission solar control film.

[0053] In other embodiments, the solar control layer 300 can be an infrared absorbing layer or an infrared reflecting layer, which is a fixed transmission solar control layer. Other variable transmission and fixed transmission technologies are also contemplated. For example, metal oxide nanoparticles, infrared absorbing nanoparticles (such as antimony tin oxide ("ATO") and ITO), metal boride nanoparticles, and metallized substrate films (such as aluminum or silver deposited by vacuum deposition or sputtering) can be used for solar control layers. In some embodiments, a solar control layer that removes energy from light in the visible range can be used. In some embodiments, the solar control layer can be a laminate that is substantially transparent and suitable for window units.

[0054] IR reflective films that incorporate metals and / or metal oxides to shield radiation in the invisible range can be used for these subcomponents. In some embodiments, a transparent metal layer or a series of metal and dielectric layers can be applied by sputtering deposition, vacuum deposition or other processes. For example, a silver layer or a silver-gold alloy layer can be applied. In some embodiments, the dielectric material can be zirconium oxide, tantalum oxide, tungsten oxide, indium tin oxide, etc. In some embodiments, a sandwich subcomponent or a laminate for a window unit can include an IR reflective film.

[0055] In some embodiments, a low emissivity layer may be employed, and such layer may include a sputter deposited silver layer between dielectric layers (e.g., titanium oxide). In some embodiments, silicon dioxide or silicon dioxide-based materials may be applied in a sol-gel process. In some embodiments, a sandwich subassembly or laminate for a window unit may include a low emissivity layer.

[0056] In certain embodiments, polymer or TPU interlayer 301,302 can be formed by using flat die extrusion.Interlayer 301,302 can be an encapsulation connection layer adhered to substrate 300 and rigid outer layer 100,101.In some embodiments, layer 100,101 can be a rigid sheet, such as glass plate, for example, and can be any glass material mentioned herein.In some embodiments, the interlayer or interlayer 301,302 can also have excellent optical transparency, durability, suitable thermal properties to compensate for the difference in thermal expansion coefficient of different layers, and the mechanical properties required for windows in automobiles, other vehicles and / or buildings.In certain embodiments, interlayer 301,302 gives composite structure impact resistance.In another example, polycarbonate (PC) can be included in interlayer 301 and 301 to give anti-bullet.In some embodiments, one or more interlayers can give composite structure structural strength and bearing capacity when the outermost glass plate fails. Examples of such encapsulating tie layers include, but are not limited to, plasticized polyvinyl butyral (PVB), ionomers, thermoplastic polyurethane (TPU), and ethylene vinyl acetate (EVA). In some embodiments, an optical TPU interlayer may be used. TPU provides good adhesion and also provides impact resistance and anti-ballistic properties.

[0057] In some embodiments, interlayers 301, 302 may have the same thickness, resulting in a symmetrical composite structure. In other embodiments, interlayers 301, 302 may have different thicknesses ranging from about 3 mils to about 100 mils; in some embodiments, from about 6 mils to about 50 mils; and in some embodiments, from about 10 mils to about 25 mils. As used herein, one mil is one thousandth of an inch.

[0058] In some embodiments, interlayers 301, 302 can be two different polymer materials of equal or unequal thickness. For example, at least one of interlayers 301 and 302 can be a PVB interlayer, an acoustic grade interlayer (which can include PVB or polyvinyl acetal (PVA)), a solar control interlayer, a structural interlayer (which can include PVB or an ionomer), an EVA interlayer, an optical grade interlayer, a solar collection component (e.g., a photovoltaic component and / or an electrochromic component). In certain embodiments, the acoustic interlayer can have a stack of PVB, PET, acrylate, PET, and PVB. In some embodiments, an acrylate acoustic layer is used.

[0059] As mentioned above, interlayers 301, 302 can be two different polymer materials of equal or unequal thickness. Examples include, but are not limited to: (a) standard PVB interlayer containing 38 phr triethylene glycol bis (2-ethylhexanoate) plasticizer; (b) acoustic grade PVB interlayer, such as Eastman Saflex Eastman Saflex Seksisui and Kuraray acoustic grade (c) solar control PVB, TPU or ionomer interlayer to reduce heat gain; (d) structural PVB interlayer containing 20 phr triethylene glycol bis(2-ethylhexanoate); (e) structural ionomer, such as Kuraray's SentryGlas Plus; (f) optical grade EVA interlayer; (g) energy collection interlayer containing inorganic quantum dots or other solar concentrators; and / or (h) ion conductive interlayer, such as described in U.S. patent application Ser. No. 17 / 550,090, filed on Dec. 14, 2021, entitled “Optically Transparent Polymer Electrolyte Films” (“the '090 Application”), the entire disclosure of which is hereby incorporated herein by reference. In certain embodiments, the electrolyte disclosed in the '090 Application can be used in an electrochromic component with a transparent electrode. In certain embodiments, the electrolyte can be a transparent ion conductive interlayer membrane. The ion conductive interlayer membrane can include thermoplastic polyurethane (TPU) or polymethyl methacrylate (PMMA). In some embodiments, the ion-conducting interlayer film may include an organic carbonate. In some embodiments, the ion-conducting interlayer film may include a dibenzoate or an acrylic monomer. In some embodiments, other types of components may be incorporated, such as photovoltaic components for generating electricity using sunlight.

[0060] In some embodiments, the rigid outer layer or substrate 100, 101 can be a substantially transparent, abrasion resistant and / or chemically inert substrate, such as soda lime glass, chemically or thermally tempered glass, or a coated glass product having solar control features, such as SUNGATET from PPG Industries, Inc. TM Windshield and SOLARSHIELD from AFG Industries, Inc. TM Glass. In some embodiments, one or more sheets of window glass, flat glass, silicate glass, or sheet glass can be used. In some embodiments, optically transparent rigid polymer sheets (e.g., polycarbonate sheets) can be used as layer 100, layer 101, or both. In some embodiments, rigid sheets of acrylates, polyacrylates, polymethyl methacrylates can be used.

[0061] exist Figure 4 In the exemplary embodiment shown, the subcomponent 356 can have a solar control layer 350, a TPU layer 352 formed on a first side of the solar control layer 350, and a layer 354 selected from polyvinyl butyral (PVB), polymethyl methacrylate (PMMA), polycarbonate (PC), or another polymer on a second side opposite the TPU layer 352. The layer 354 on the second side opposite the TPU layer 352 can provide acoustic damping or other features. In some embodiments, a second layer of TPU or other adhesive polymer can be formed on the layer 354. The subcomponent 356 having one or more layers of TPU or other adhesive polymer can be provided on a roll. In some embodiments, the solar control layer 350 can act as a carrier layer, for example by providing or acting as an electrochromic component, an infrared absorbing layer, an infrared reflecting layer, or a low emissivity layer.

[0062] Disclosed herein is an exemplary method of making a sandwich subcomponent with the carrier layer. It is possible to lay down each layer 300, 301, and 302 separately before lamination. However, this will make the lamination process complicated, expensive, and time consuming. In certain embodiments, the sandwich layers 301, 302 can be extruded separately or simultaneously onto the solar control layer 300, which can serve as a carrier layer in this context. In some embodiments, the layers 300, 301, and 302 can be combined into a single multilayer subcomponent, which can be sold in rolls and cut to the appropriate size before lamination.

[0063] In certain embodiments, a pre-existing solar control layer 300 may be obtained and used as a support on which to cast at least one adhesive layer. For example, adhesive layers 301 and 302 may be cast onto pre-existing solar control layer 300. Suitable solar control layers that are readily commercially available from various suppliers may be employed. Examples include Eastman Chemical Company's XIR-70, XIR-75, V-Kool, and Hüper Optik TM Film, ULTRA PERFORMANCE of Bekaert SpecialtyFilms, LLC TM 75 membrane, Sekisui Chemical Co.'s S-LEC TM Acoustic and solar films and 3M's Prestige Series window films.

[0064] Figure 5 A schematic diagram of an exemplary system for applying an adhesive layer to a side of a solar control layer is shown, according to some embodiments. System 400 can be configured to perform the first pass of a two-pass process for applying a first layer of adhesive and a second layer of adhesive to the solar control layer in separate passes by system 400. In some embodiments, system 400 can be used to apply a single layer of adhesive to the solar control layer. These systems can be used to form sandwich subcomponents having at least one layer of adhesive on a solar control layer or other functional layer for incorporation into a laminate for a window unit.

[0065] like Figure 5 As shown, flat die 402 can be fed by a single screw or twin screw extruder to extrude adhesive layer 414. Solar control layer 412 can be provided on roller 408. When solar control layer 412 is unfolded, adhesive layer 414 can be cast or extruded onto the side of solar control layer 412 and passed through a pair of nip rollers 404 and 406. In this case, solar control layer 412 acts as a carrier layer without the need for additional PET or PEN layers. The resulting sandwich sub-components 415 can be gathered on winder 410. In certain embodiments, a melt pump can be located near mold 402, or hot air can be blown to the adhesive to maintain the desired degree of viscosity in the material. The adhesive can be a thermoplastic polyurethane (TPU) that has adhesiveness when heated. Other polymer coatings can be used, such as polyvinyl butyral (PVB) and ethylene vinyl acetate (EVA).

[0066] Figure 6A schematic diagram of an exemplary system 500 for applying an adhesive layer to the side of solar control layer 412 opposite adhesive 414 is shown. System 500 can be configured similarly to system 400, such that the coated solar control layer 412 can be passed through the system a second time to coat the opposite side of solar control layer 412. In some embodiments, a separate system 500 can be placed adjacent to system 400 for applying a second coating of adhesive.

[0067] like Figure 6 As shown, flat die 502 can be fed by a single screw or twin screw extruder to extrude adhesive layer 514. Subcomponent 415 can be provided on roller 508. When subcomponent 415 is unfolded, adhesive layer 514 is cast onto the side of solar control layer 412 opposite to adhesive 414 and passes through a pair of nip rollers 504 and 506. Solar control layer 412 can act as a carrier layer without additional PET or PEN layers. Sandwich subcomponent 515 can be gathered on winder 510 and have a first adhesive layer on the first side of the solar control layer and a second adhesive layer on the second side of the solar control layer. In some embodiments, a melt pump can be located near mold 502, or hot air can be blown to the adhesive to maintain the desired degree of viscosity in the material. Adhesive 514 can be a thermoplastic polyurethane (TPU) with adhesiveness when heated. Other polymer coatings can be used, such as polyvinyl butyral (PVB) and ethylene vinyl acetate (EVA).

[0068] In further embodiments, system 500 can be used to coat solar control layer 412 with PVB, PMMA, PC, or other polymer on the side opposite adhesive layer 414. In certain embodiments, a TPU or other adhesive layer can be coated on the assembly on the opposite side of layer 414. In some embodiments, two interlayers can be cast simultaneously using a single sheeting die or two sheeting dies.

[0069] It is contemplated that a window unit 602 may be provided having a solar control sandwich subassembly 610, such as Figure 7As shown. The sandwich subcomponent 610 may be provided in the window frame 612. In other contemplated embodiments, other structures and components may also be included, for example, an acoustic grade layer that may include PVB or polyvinyl acetal (PVA), a structural layer that may include PVB or an ionomer, a solar energy collection component, such as a photovoltaic component and / or an electrochromic component. In certain embodiments, the window unit may be used on a specific side of a building and may include a transparent portion and a translucent or opaque portion. For example, the transparent portion may include energy collection aspects, such as quantum dots arranged within the transparent portion, and the photovoltaic cells are arranged in a portion that is not relied upon to achieve transparency, such as an opaque portion that does not constitute part of the window area. In other embodiments, the photovoltaic cells may be located at one or more edges of the laminate or window unit.

[0070] Example

[0071] Exemplary interlayer and laminate samples described herein were prepared and evaluated.

[0072] Example 1

[0073] The three-layer film is formed by disposing a first thermoplastic polyurethane layer on one side of a carrier layer having a solar control function, and further disposing a second thermoplastic polyurethane layer on a second side of the carrier layer, wherein the second side is opposite to the first side. The first and second thermoplastic polyurethane layers are made of aliphatic polyether resin (produced by BASF as L1275A10) and has a nominal thickness of 0.025 inches or 0.635 mm. The carrier layer with solar control function is architectural window film C-1, sold by Madico as Solar Grey 35. It transmits 32.3% of visible light and has a haze of 1.03%. The three-layer film is further encapsulated between two rigid borosilicate glass plates (each 0.125 inches or 3.175 mm thick) and laminated using a vacuum autoclave at a temperature of 239°F and a pressure of 100 psi. The light transmittance and haze of the resulting laminates S-1A and S-1B average 37.7% and 1.31%, respectively.

[0074] Example 2

[0075] The three-layer film is formed by disposing a first thermoplastic polyurethane layer on one side of a carrier layer having a solar control function, and further disposing a second thermoplastic polyurethane layer on a second side of the carrier layer, wherein the second side is opposite to the first side. The first and second thermoplastic polyurethane layers are made of aliphatic polyether resin (produced by BASF as L1275A10) and has a nominal thickness of 0.025 inches or 0.635 mm. The carrier layer with solar control function is architectural window film C-2, sold by Madico as Solar Bronze 35. It transmits 34.1% of visible light and has a haze of 1.09%. The three-layer film is further encapsulated between two rigid borosilicate glass plates (each 0.125 inches or 3.175 mm thick) and laminated using a vacuum autoclave at a temperature of 239°F and a pressure of 100 psi. The light transmittance and haze of the resulting laminates S-2A and S-2B average 39.9% and 1.075%, respectively.

[0076] Example 3

[0077] The three-layer film is formed by disposing a first thermoplastic polyurethane layer on one side of a carrier layer having a solar control function, and further disposing a second thermoplastic polyurethane layer on a second side of the carrier, wherein the second side is opposite to the first side. The first and second thermoplastic polyurethane layers are made of aliphatic polyether resin (produced by BASF as L1275A10) and is labeled as 0.025 inches or 0.635 mm thick. The carrier layer with solar control function is architectural window film C-3, which is manufactured by Madico as Reflective 5. It transmits 6.53% of visible light and has a haze of 3.72%. The three-layer film was further encapsulated between two rigid borosilicate glass plates (each 0.125 inches or 3.175 mm thick) and laminated using a vacuum autoclave at a temperature of 239°F and a pressure of 100 psi. The light transmittance and haze of the resulting laminates S-3A and S-3B averaged 6.635% and 4.485%, respectively.

[0078] Comparative Example 1

[0079] The two laminates are constructed by laying down two layers of thermoplastic polyurethane, which is composed of an aliphatic polyether resin (produced by BASF as L1275A10) was extruded. The nominal thickness of each layer was 0.025 inches or 0.635 mm. The two layers were further encapsulated between two rigid borosilicate glass plates (each 0.125 inches or 3.175 mm thick) and laminated using a vacuum autoclave at a temperature of 239°F and a pressure of 100 psi. No carrier layer was provided between the two thermoplastic polyurethane layers. The light transmittance and haze of the resulting laminates CS-1A and CS-2A averaged 93.5% and 0.83%, respectively.

[0080] As can be seen from Examples 1-3 and Comparative Example 1, and as summarized in Table 1, providing thermoplastic polyurethane layers on the first and second sides of the functional carrier layer and further laminating the three layers between two rigid glass plates does not have too adverse an effect on the light transmittance and haze values ​​of the resulting composite material.

[0081] Table 1: Transmittance and haze values ​​of functional carrier, Examples 1-3 and Comparative Example 1.

[0082]

[0083] As shown in Table 1 above, although the light transmittance and haze of all three examples increased compared to the respective functional carrier films, the optical performance was still acceptable.

[0084] Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the embodiments disclosed herein. It is intended that the specification and examples be considered exemplary only, with a true scope and spirit of the embodiments being indicated by the following claims.

[0085] For example, according to one aspect, in a first embodiment, a sandwich subcomponent is provided. The sandwich subcomponent may include a carrier layer and at least one thermoplastic polyurethane layer on its side, wherein the at least one thermoplastic polyurethane layer has adhesion when heated, and the carrier layer is a solar control layer.

[0086] The second embodiment is the first embodiment of the sandwich subassembly, wherein the carrier layer is an electrochromic component, an infrared absorbing layer, an infrared reflecting layer, or a low emissivity layer.

[0087] The third embodiment is any combination of the first two embodiments, wherein the thermoplastic polyurethane layer is an optical interlayer formed by extrusion.

[0088] The fourth embodiment is any combination of the first three embodiments, wherein the first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and the second thermoplastic polyurethane layer is disposed on a second side of the carrier layer, the second side being opposite to the first side, and the first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer are adhesive when heated.

[0089] A fifth embodiment is any combination of the first four embodiments, wherein the first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer have the same thickness.

[0090] A sixth embodiment is any combination of the first five embodiments, wherein the first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer have different thicknesses.

[0091] A seventh embodiment is any combination of the first six embodiments, wherein the first thermoplastic polyurethane layer, the second thermoplastic polyurethane layer, or both thermoplastic polyurethane layers are wedge-shaped.

[0092] An eighth embodiment is any combination of the preceding seven embodiments, wherein the subcomponent forms part of a head-up display (HUD) window unit.

[0093] The ninth embodiment is any combination of the first eight embodiments, wherein the first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and further comprises a second layer on a second side opposite to the first side, the second layer being selected from the group consisting of polyvinyl butyral, polymethyl methacrylate, poly(ethylene-co-acrylic acid), an alkali metal salt of poly(ethylene-co-acrylic acid), and poly(ethylene-co-vinyl acetate).

[0094] A tenth embodiment is any combination of the first nine embodiments, wherein a second thermoplastic polyurethane layer is disposed on the second layer.

[0095] An eleventh embodiment is any combination of the preceding ten embodiments, wherein the first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and further comprising a layer on a second side of the carrier layer that provides acoustic damping.

[0096] A twelfth embodiment is any combination of the previous eleven embodiments, wherein the first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and further comprising a layer on a second side of the carrier layer that provides impact resistance.

[0097] A thirteenth embodiment is any combination of the previous twelve embodiments, wherein the first thermoplastic polyurethane layer is disposed on the second side of the carrier layer, and further comprising a photovoltaic module on the first side of the carrier layer.

[0098] A 14th embodiment is any combination of the previous 13 embodiments, wherein the first side is an outward facing side of the window unit.

[0099] A fifteenth embodiment is any combination of the previous fourteen embodiments, wherein the photovoltaic module comprises a polymer layer having a photovoltaic cell.

[0100] A sixteenth embodiment is any combination of the preceding fifteen embodiments, wherein the photovoltaic module comprises a polymer layer having quantum dots.

[0101] A seventeenth embodiment is any combination of the previous sixteen embodiments, further comprising a photovoltaic cell disposed along an edge of the carrier layer.

[0102] An eighteenth embodiment is any combination of the previous seventeen embodiments, further comprising a photovoltaic cell disposed on a surface of the carrier layer that is not relied upon to achieve transparency.

[0103] A 19th embodiment is any combination of the previous 18 embodiments, wherein the first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and further comprising an electrochromic component on a second side of the carrier layer.

[0104] The twentieth embodiment is any combination of the preceding nineteen embodiments, wherein the electrochromic component comprises a transparent ion-conducting polymer electrolyte membrane.

[0105] A 21st embodiment is any combination of the previous 20 embodiments, wherein the electrochromic component comprises a transparent electrode.

[0106] The twenty-second embodiment is any combination of the previous twenty-first embodiments, wherein the first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and further comprises a polyvinyl butyral layer on a second side of the carrier layer.

[0107] The 23rd embodiment is any combination of the previous 22 embodiments, wherein the first thermoplastic polyurethane layer is disposed on a first side of the carrier layer and further comprises a poly(ethylene vinyl acetate) layer on a second side of the carrier layer.

[0108] In a second aspect, a first embodiment of a window unit for a vehicle or a building is provided, wherein the window unit has a sandwich subcomponent according to any combination of the first 23 embodiments described above disposed between a first rigid sheet and a second rigid sheet.

[0109] A second embodiment is the first embodiment of the window unit, wherein at least one of the first rigid sheet and the second rigid sheet comprises glass.

[0110] A third embodiment is any combination of the previous two embodiments of the window unit, wherein at least one of the first rigid sheet and the second rigid sheet comprises a polymer.

[0111] A fourth embodiment is any combination of the preceding three embodiments of the window unit, further comprising electromagnetic shielding.

[0112] A fifth embodiment is any combination of the preceding four embodiments of the window unit, further comprising a low emissivity layer.

[0113] A sixth embodiment is any combination of the preceding five embodiments of the window unit, further comprising an electrochromic component.

[0114] A seventh embodiment is any combination of the preceding six embodiments of a window unit, further comprising a photovoltaic assembly.

[0115] In a third aspect, a first embodiment of a method of forming a sandwich subcomponent is provided. The method includes providing a carrier layer, the carrier layer being a solar control layer, and extruding a thermoplastic polyurethane layer on a side of the carrier layer, the thermoplastic polyurethane layer being adhesive when heated.

[0116] A second embodiment is the first embodiment of the foregoing method, wherein the solar control layer is an electrochromic component, an infrared reflecting layer, an infrared absorbing layer, or a low emissivity layer.

[0117] The third embodiment is any combination of the preceding two embodiments of the method, wherein a first thermoplastic polyurethane layer is extruded on a first side of the carrier layer, and further comprises extruding a second thermoplastic polyurethane layer on a second side of the carrier layer, the first side being opposite to the second side.

[0118] A fourth embodiment is any combination of the preceding three embodiments of the method, wherein in a first pass a first thermoplastic polyurethane layer is extruded onto a first surface of the carrier layer, and in a second pass a second thermoplastic polyurethane layer is extruded onto a second surface of the carrier layer.

[0119] A fifth embodiment is any combination of the preceding four embodiments of the process, wherein the first pass and the second pass are performed by the same extruder.

[0120] A sixth embodiment is any combination of the preceding five embodiments of the method, wherein the first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer are extruded simultaneously.

[0121] A seventh embodiment is any combination of the preceding six embodiments of the method, further comprising gathering the sandwich subcomponents into a roll.

[0122] The eighth embodiment is any combination of the preceding seven embodiments of the method, wherein a first thermoplastic polyurethane layer is extruded on a first side of the carrier layer, and further comprising extruding a second layer on a second side of the carrier layer, the first side being opposite to the second side, the second layer being selected from the group consisting of polyvinyl butyral, polymethyl methacrylate, and polycarbonate.

[0123] A ninth embodiment is any combination of the preceding ten embodiments of the method, further comprising laminating a sandwich subcomponent with a first rigid sheet and a second rigid sheet, the sandwich subcomponent being disposed between the first rigid sheet and the second rigid sheet.

[0124] The tenth embodiment is any combination of the preceding eleven embodiments of the method, wherein at least one of the first rigid sheet and the second rigid sheet comprises glass.

[0125] An eleventh embodiment is any combination of the preceding ten embodiments of the method, wherein at least one of the first rigid sheet and the second rigid sheet is a polymeric rigid sheet.

Claims

1. A sandwich subcomponent comprising: a carrier layer and at least one thermoplastic polyurethane layer on its side, The at least one thermoplastic polyurethane layer has adhesive properties when heated, and the carrier layer is a solar control layer.

2. The sandwich subcomponent according to claim 1, wherein the carrier layer is an electrochromic component, an infrared absorbing layer, an infrared reflecting layer or a low emissivity layer.

3. The sandwich subcomponent according to claim 1, wherein the thermoplastic polyurethane layer is an optical sandwich formed by extrusion.

4. The sandwich subcomponent according to claim 1, wherein a first thermoplastic polyurethane layer is arranged on a first side of the carrier layer, and a second thermoplastic polyurethane layer is arranged on a second side of the carrier layer, the second side is opposite to the first side, and the first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer are adhesive when heated. 5 . The sandwich subcomponent according to claim 4 , wherein the first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer have the same thickness. 6 . The sandwich subcomponent according to claim 4 , wherein the first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer have different thicknesses.

7. The sandwich subcomponent of claim 4, wherein the first thermoplastic polyurethane layer, the second thermoplastic polyurethane layer, or both thermoplastic polyurethane layers are wedge-shaped.

8. The sandwich subassembly of claim 7, wherein the subassembly forms part of a head-up display (HUD) window unit.

9. The sandwich subcomponent according to claim 1, wherein a first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and the sandwich subcomponent further comprises a second layer on a second side opposite to the first side, the second layer being selected from the group consisting of polyvinyl butyral, polymethyl methacrylate, poly(ethylene-co-acrylic acid), alkali metal salts of poly(ethylene-co-acrylic acid), and poly(ethylene-co-vinyl acetate).

10. The sandwich subcomponent according to claim 9, wherein a second thermoplastic polyurethane layer is arranged on the second layer.

11. The sandwich subcomponent according to claim 1, wherein a first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and the sandwich subcomponent further comprises a layer on a second side of the carrier layer providing acoustic damping.

12. The sandwich subcomponent according to claim 1, wherein a first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and the sandwich subcomponent further comprises a layer on a second side of the carrier layer providing impact resistance.

13. The sandwich subcomponent according to claim 1, wherein a first thermoplastic polyurethane layer is disposed on the second side of the carrier layer, and the sandwich subcomponent further comprises a photovoltaic module on the first side of the carrier layer.

14. The sandwich subcomponent of claim 13, wherein the first side is an outwardly facing side of the window unit.

15. The sandwich subcomponent according to claim 13, wherein the photovoltaic module comprises a polymer layer having photovoltaic cells.

16. The sandwich subassembly of claim 13, wherein the photovoltaic component comprises a polymer layer having quantum dots.

17. The sandwich subcomponent according to claim 16, further comprising photovoltaic cells arranged along the edge of the carrier layer.

18. The sandwich subcomponent of claim 16, further comprising a photovoltaic cell disposed on a surface of the carrier layer that is not relied upon to achieve transparency.

19. The sandwich subcomponent of claim 1, wherein a first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and the sandwich subcomponent further comprises an electrochromic component on a second side of the carrier layer.

20. The sandwich subassembly of claim 19, wherein the electrochromic component comprises a transparent ion-conducting polymer electrolyte membrane.

21. The sandwich subassembly of claim 19, wherein the electrochromic component comprises a transparent electrode.

22. The sandwich subcomponent of claim 1, wherein a first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and the sandwich subcomponent further comprises a polyvinyl butyral layer on a second side of the carrier layer.

23. The sandwich subcomponent of claim 1, wherein a first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and the sandwich subcomponent further comprises a poly(ethylene-co-vinyl acetate) layer on a second side of the carrier layer.

24. A window unit for a vehicle or a building having a sandwich subcomponent according to claim 1 disposed between a first rigid sheet and a second rigid sheet.

25. The window unit of claim 24, wherein at least one of the first rigid sheet and the second rigid sheet comprises glass.

26. The window unit of claim 24, wherein at least one of the first rigid sheet and the second rigid sheet comprises a polymer.

27. The window unit of claim 24, further comprising an electromagnetic shield.

28. The window unit of claim 24, further comprising a low emissivity layer.

29. The window unit of claim 24, further comprising an electrochromic component.

30. The window unit of claim 24, further comprising a photovoltaic assembly.

31. A method of forming a sandwich subcomponent, wherein include: providing a carrier layer, the carrier layer being a solar control layer; and A thermoplastic polyurethane layer is extruded on the side of the carrier layer, and the thermoplastic polyurethane layer has adhesiveness when heated.

32. The method of claim 31 , wherein the solar control layer is an electrochromic component, an infrared reflecting layer, an infrared absorbing layer, or a low emissivity layer.

33. The method of claim 31 , wherein a first thermoplastic polyurethane layer is extruded on a first side of the carrier layer, and the method further comprises extruding a second thermoplastic polyurethane layer on a second side of the carrier layer, the first side being opposite to the second side.

34. The method of claim 33, wherein the first thermoplastic polyurethane layer is extruded onto a first surface of the carrier layer in a first pass and the second thermoplastic polyurethane layer is extruded onto a second surface of the carrier layer in a second pass.

35. The method of claim 34, wherein the first pass and the second pass are performed by the same extruder.

36. The method of claim 34, wherein the first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer are extruded simultaneously.

37. The method of claim 31 further comprising gathering the sandwich subcomponents into a roll.

38. The method of claim 31, wherein a first thermoplastic polyurethane layer is extruded on a first side of the carrier layer, and the method further comprises extruding a second layer on a second side of the carrier layer, the first side being opposite to the second side, the second layer being selected from the group consisting of polyvinyl butyral, polymethyl methacrylate, and polycarbonate.

39. The method of claim 31 further comprising laminating the sandwich subcomponent with a first rigid sheet and a second rigid sheet, the sandwich subcomponent being disposed between the first rigid sheet and the second rigid sheet.

40. The method of claim 39, wherein at least one of the first rigid sheet and the second rigid sheet comprises glass.

41. The method of claim 39, wherein at least one of the first rigid sheet and the second rigid sheet is a polymeric rigid sheet.

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