Interlayer with functional properties for laminated assemblies

Abstract

Interlayers for laminates and laminates are provided that can be used in a variety of different applications, such as windows for vehicles and buildings, impact resistant devices such as ballistic resistant glasses, decorative films for windows, walls or doors, window films, colored or mirror glasses, window films, and the like. The intermediate layer includes an adhesive film having a monolithic structure that includes thermoplastic polyurethane (TPU). The film includes one or more functional elements disposed within its unitary structure, and has a thickness of at least about 0.015 inches. The intermediate layer is a single TPU layer having both adhesive properties and functional properties such that the intermediate layer can be connected to one or more outer transparent layers in a laminated assembly that is particularly suitable for use, for example, in applications requiring solar control functions, such as windows that absorb or reflect heat, IR and / or UV light, etc.

Description

Cross-reference to related applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 578,437, filed August 24, 2023, the entire disclosure of which is incorporated herein by reference for all purposes. Technical Field

[0002] This specification generally relates to intermediate layers for laminated components, which have functional characteristics such as solar control functions and / or optical elements such as UV absorbers, UV reflectors, IR absorbers, IR reflectors, etc. Background Technology

[0003] A laminated glazing unit (LGU) is a laminated assembly comprising one or more interlayer sheets inserted between clear rigid sheets. The rigid sheets can be glass or any other known alternative, such as polycarbonate, acrylic resin, polyester, and rigid clear polyurethane. The interlayers bond adjacent rigid sheets together to form a unified laminated assembly; these interlayers can be thermoplastic materials such as polyvinyl formal, polyvinyl butyral, polyvinyl isobutyral, silicone, or ethylene vinyl acetate (EVA).

[0004] In recent years, the performance requirements for such laminated materials used in the automotive and construction markets have far exceeded simple optical transparency and impact resistance. LGUs have become an important component of commercial and residential buildings, often as an integral part of the building structure itself. In this context, there is a growing expectation that the intermediate layer can provide solar control functions to reduce the load on building HVAC systems, improve vehicle cabin comfort and energy efficiency, and so on. With the advancement of photovoltaic technology, building-integrated photovoltaics (BIPV) is also becoming increasingly popular. In the latter case, the LGU is combined with photovoltaic cells located at the edge of the laminated module, using various light-emitting sources, including but not limited to inorganic semiconductor quantum dots, to waveguide incident solar radiation to the edge.

[0005] In the automotive or construction markets, traditional interlayers used for lamination between external transparent layers such as glass include plasticized polyvinyl butyral (PVB). Plasticized PVB is typically produced through an extrusion process, exhibits good adhesion to glass, and offers excellent optical transparency, good durability, and high impact resistance.

[0006] Current technology for producing laminated structures with solar control capabilities requires two thick (0.015 inch to 0.050 inch) adhesive interlayers (such as PVB) and a thin (0.002 inch) functional film with solar control properties. The thicker interlayer provides the adhesive properties required for lamination with glass or similar materials, while the thinner functional film provides the solar control characteristics. Summary of the Invention

[0007] This application provides an intermediate layer and a laminate for use in laminated materials, which can be used in a variety of different applications, such as windows for vehicles and buildings, impact-resistant devices such as bulletproof glass, decorative films for windows, walls or doors, window films, tinted or mirrored glass, window film, etc.

[0008] In one aspect, the intermediate layer for the laminate includes an adhesive film having an integral structure comprising thermoplastic polyurethane (TPU). The film includes one or more functional elements within the integral structure, and the film thickness is at least about 0.015 inches. This intermediate layer is a single TPU layer possessing both adhesive properties and functional characteristics, enabling it to be bonded to one or more outer transparent layers in a laminated assembly, particularly suitable for applications requiring solar energy control functions, such as windows that absorb or reflect heat, IR, and / or UV light.

[0009] In some embodiments, the intermediate layer may be adhered to a single outer layer. In other embodiments, the intermediate layer may be adhered to a first and a second outer layer located on opposite surfaces of the intermediate layer. The first and / or second outer layer may comprise any optically transparent material with sufficient rigidity suitable for a particular application. Suitable materials for the outer layers include, but are not limited to, glass, artificial glass, polycarbonate, acrylic resin, polyester, polyether, and polyurethane. In exemplary embodiments, the outer layer comprises glass, polycarbonate, or acrylic.

[0010] In one implementation, the thickness of the TPU interlayer is about 0.015 inches to about 0.10 inches, or about 0.015 inches to about 0.04 inches, or about 0.02 inches to about 0.025 inches.

[0011] The TPU layer may comprise any suitable thermoplastic polyurethane, such as polyester, polyether, polycaprolactone, etc. In an exemplary embodiment, the TPU layer comprises an aliphatic TPU, preferably a polyether aliphatic TPU. The hardness range of the polyether aliphatic TPU may be from about 60 Shore A to about 100 Shore A, or from about 70 Shore A to about 85 Shore A.

[0012] In this embodiment, the intermediate layer is substantially optically transparent. Therefore, the haze of the intermediate layer may be less than about 4%, less than about 3%, less than or equal to about 1.7%, or less than or equal to about 1%. The visible light transmittance (VLT%) of the intermediate layer may be greater than about 30%, greater than about 50%, greater than about 70%, greater than about 80%, or about 86% or greater. The ultraviolet-visible spectral transmittance (UV-VIS) of the intermediate layer may be less than about 10%, less than about 5%, or less than or equal to about 1%. The yellowness index (E313) of the intermediate layer may be less than about 6, less than about 5, less than about 4, or less than about 2.

[0013] In one embodiment, the intermediate layer can substantially block or reflect specific wavelengths in the 100-400 nm range. In one such embodiment, the light transmittance of the intermediate layer at 380 nm can be less than about 0.1%, less than about 0.05%, or less than or equal to about 0.04%. The light transmittance of the intermediate layer at 400 nm can be less than about 50%, less than about 10%, less than about 2%, less than about 1%, or less than about 0.02%.

[0014] In this embodiment, the TPU layer includes a first upper layer and a second lower layer. The first and second layers can be extruded separately or together as part of a single process. In either process, they form a single, monolithic TPU interlayer that integrates internal solar control features. In an exemplary embodiment, the thickness of each of the first and second layers can be from about 0.005 to about 0.025 inches, preferably from about 0.005 to about 0.015 inches, or about 0.01 inches.

[0015] In one embodiment, the adhesive film further includes a third TPU layer disposed between the first TPU layer and the second TPU layer. In an exemplary embodiment, the third TPU layer preferably comprises polycaprolactone-based TPU. The hardness of the polycaprolactone-based TPU may be from about 40 Shore D to about 85 Shore D, or from about 55 Shore D to about 70 Shore D.

[0016] In one embodiment, the adhesive film includes a functional film or coating adhered to the third TPU layer. Functional features, such as solar control elements, are disposed on the functional film coating. The functional film coating and the third TPU layer may have a thickness suitable for integrating the solar control elements onto the film coating, preferably less than about 0.003 inches, less than about 0.001 inches, or about 0.0008 inches.

[0017] The functional film can be coated onto the third TPU layer by any suitable method, such as drop casting, dip coating, optical deposition, vacuum deposition, electrospinning, electrospraying, layer-by-layer deposition, spin coating, etc. In an exemplary embodiment, the functional film is sputter-coated onto the carrier film.

[0018] In one embodiment, the first TPU layer adheres to the third TPU layer, and the first TPU layer also adheres to the functional film coating. In another embodiment, the first TPU layer and the second TPU layer are simultaneously or sequentially extruded onto the third TPU layer and the functional film coating. In an exemplary embodiment, the second TPU layer is first extruded onto the functional film coating, and then the first TPU layer is extruded onto the third TPU layer to form an integral intermediate layer.

[0019] In embodiments, functional characteristics include one or more of the following: light emitters, solar energy control elements, ionomers, and optical elements (such as UV absorbers, UV reflectors, IR absorbers, and IR reflectors), and any combination thereof. Light emitters may include phosphorescent organic molecules, quantum dots, organic dyes, or combinations thereof. Optical elements may include materials that allow visible light to transmit and reflect or absorb UV and / or IR light, and / or layers made of such materials.

[0020] In implementation, the solar control element includes one or more of the following: heat absorber, heat reflector, filter, photovoltaic module, electrochromic module, and any combination thereof.

[0021] In this implementation, the intermediate layer is non-linear. The selected TPU is flexible or moldable to manufacture deformable or bending laminated components with solar energy control characteristics.

[0022] In another aspect, a laminate material comprising one of the aforementioned intermediate layers is provided.

[0023] In another aspect, a window comprising the aforementioned laminated material is provided.

[0024] In another aspect, a decorative film comprising the aforementioned laminated material is provided.

[0025] In another aspect, the laminate includes a first optically transparent outer layer and a second layer adhered to the first layer. The second layer has an integral structure comprising thermoplastic polyurethane (TPU) and includes one or more functional elements within its integral structure. The thickness of the second layer is at least about 0.015 inches.

[0026] Functional elements may include one or more of the following, such as light emitters, solar energy control elements, ionomers, and optical elements (e.g., UV absorbers, UV reflectors, IR absorbers, IR reflectors) and any combination thereof.

[0027] In one embodiment, the laminate includes a third optically transparent layer adhered to the adhesive film. A TPU layer is disposed between the first outer layer and the third outer layer. The first transparent layer and / or the third transparent layer may comprise a material selected from glass, artificial glass, polycarbonate, acrylic, polyester, polyether, and polyurethane. In an exemplary embodiment, the first and third layers comprise glass, polycarbonate, or acrylic.

[0028] In one embodiment, the first and third layers comprise glass, and the functional elements include solar control elements selected from heat absorbers, heat reflectors, filters, photovoltaic modules, electrochromic modules, and combinations thereof.

[0029] In another embodiment, the first and third layers comprise polycarbonate, and the functional elements include solar control elements selected from heat absorbers, heat reflectors, filters, photovoltaic modules, electrochromic modules, and combinations thereof. In an exemplary embodiment, the laminated assembly is impact-resistant or bulletproof.

[0030] In another embodiment, the first and third layers comprise acrylics, and the functional elements include solar control elements selected from heat absorbers, heat reflectors, filters, photovoltaic modules, electrochromic modules, and combinations thereof. In an exemplary embodiment, the laminated assembly includes a decorative layer or decorative film, such as for windows, doors, walls, or other interior or exterior parts of buildings, vehicles, etc.

[0031] In another aspect, a solar-controlled window is provided, comprising the aforementioned laminated material, wherein the first outer layer and the third outer layer comprise glass. In an exemplary embodiment, the window includes a panoramic sunroof for automobiles.

[0032] In another aspect, an impact-resistant window is provided, comprising a first rigid transparent outer layer and a second rigid transparent outer layer, as well as the aforementioned laminated material. The first and second outer layers comprise polycarbonate.

[0033] In another aspect, a decorative layer or decorative film is provided, comprising one of the aforementioned laminated materials, wherein the first outer layer and the second outer layer comprise acrylics.

[0034] In an exemplary embodiment, a functional glass and artificial glass laminate is provided, integrating an electrochromic module and a photovoltaic module, with the photovoltaic module powering the electrochromic module. In some embodiments, an additional layer may be added to the electrochromic module on the side away from the photovoltaic module to further insulate the building or vehicle interior from additional heat generated when the laminate is used as a window, skylight, etc. This laminate can be integrated into a freestanding window unit, eliminating the need for external wiring connections, thereby improving the energy efficiency of the building or vehicle.

[0035] In another aspect, the intermediate layer for the laminate material includes a first thermoplastic polyurethane (TPU) layer, a second TPU layer, and a third polymer layer disposed between the first polymer layer and the second polymer layer, the third polymer layer including one or more functional elements.

[0036] In one embodiment, the third polymer layer comprises TPU.

[0037] In one embodiment, the intermediate layer further includes a coating on the third polymer layer, wherein one or more functional elements are disposed on the coating. The coating may be applied to the third polymer layer by any suitable means. In one embodiment, the coating is sputtered onto the third TPU layer.

[0038] In this implementation, the thickness of the coating and the third TPU layer is less than about 0.003 inches.

[0039] In one embodiment, the intermediate layer further includes an optical material on the first TPU layer, the optical material being configured to reflect or absorb UV light. The intermediate layer may include a second optical material on the second TPU layer, the second optical material being configured to reflect or absorb UV light.

[0040] In one embodiment, the first, second, and third layers form an integral structure with a thickness of at least about 0.015 inches, or about 0.015 to about 0.1 inches.

[0041] In this embodiment, the intermediate layer is substantially optically transparent. Therefore, the haze of the intermediate layer may be less than about 4%, less than about 3%, less than or equal to about 1.7%, or less than or equal to about 1%. The visible light transmittance (VLT%) of the intermediate layer may be greater than about 30%, greater than about 50%, greater than about 70%, greater than about 80%, or about 86% or greater. The ultraviolet-visible spectral transmittance (UV-VIS) of the intermediate layer may be less than about 10%, less than about 5%, or less than or equal to about 1%. The yellowness index (E313) of the intermediate layer may be less than about 6, less than about 5, less than about 4, or less than about 2.

[0042] In one embodiment, the intermediate layer can substantially block or reflect specific wavelengths in the 100-400 nm range. In one such embodiment, the light transmittance of the intermediate layer at 380 nm can be less than about 0.1%, less than about 0.05%, or less than or equal to about 0.04%. The light transmittance of the intermediate layer at 400 nm can be less than about 50%, less than about 10%, less than about 2%, less than about 1%, or less than about 0.02%. Attached Figure Description

[0043] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the present disclosure and, together with the specification, serve to explain the principles of the present disclosure.

[0044] Figure 1 This is a schematic cross-sectional view of a multilayer laminated material according to an exemplary embodiment; Figure 2 This is a schematic cross-sectional view of a multilayer laminated material according to another exemplary embodiment; Figure 3 It is a graph showing the light transmittance values ​​at a series of wavelengths; Figure 4 The light transmission spectra of certain multilayer laminates described in this application are shown; Figure 5The light transmission spectra of certain multilayer laminates described in this application are shown in the range of 360 nm to 420 nm. Detailed Implementation

[0045] This specification and accompanying drawings illustrate exemplary embodiments and should not be considered limiting. The claims (including equivalents) define the scope of this disclosure. Various mechanical, compositional, structural, and operational changes may be made without departing from the scope of this specification and the claims (including equivalents). In some cases, well-known structures and techniques have not been shown or described in detail so as not to obscure this disclosure. Identical numbers in two or more drawings denote identical or similar elements. Furthermore, elements and related aspects described in detail with reference to one embodiment may be incorporated into other embodiments, where practically feasible, even if not specifically shown or described. For example, if an element is described in detail with reference to one embodiment but not with reference to a second embodiment, that element may still be claimed for inclusion in the second embodiment. Furthermore, the illustrations in this application are for illustrative purposes only and do not necessarily reflect the actual shape, size, or dimensions of the system or the components shown.

[0046] It should be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the,” as well as the singular use of any word, including plural references, are used unless explicitly and unambiguously limited to a single referent. As used in this application, the term “comprising” and its grammatical variations are intended to be non-restrictive, such that the listing of items does not exclude other similar items that may be substituted for or added to the listed items.

[0047] This application provides an intermediate layer for a laminate and a laminate including the intermediate layer, which can be used in a variety of different applications, such as windows for vehicles and buildings, impact-resistant devices such as bulletproof glass, decorative films for windows, walls or doors, window films, tinted or mirrored glass, window films, etc. This laminate is particularly suitable for applications requiring solar energy control functions, such as windows that absorb or reflect heat, IR and / or UV light. The laminate is preferably optically transparent and exhibits photoelectric properties.

[0048] In some implementations, such as Figure 1 As shown, the laminate 100 includes a first optically transparent layer and second optically transparent layers 110 and 120, and an adhesive intermediate layer 125 laminated between the first and second outer layers 110 and 120. The intermediate layer 125 is a monolithic structure comprising thermoplastic polyurethane (TPU) having sufficient thickness to adhere to the outer layers 110 and 120, preferably at least about 0.015 inches thick. In this application, monolithic is defined as a single, substantially indivisible layer of material.

[0049] One or more functional elements are included within or otherwise disposed therein in the integral structure of the intermediate layer 125. Suitable functional elements include, but are not limited to, solar control elements, light emitters, ionomers, and optical elements such as UV absorbers, UV reflectors, IR absorbers, IR reflectors, etc. In one embodiment, the functional element includes a solar control element. Suitable solar control elements include, but are not limited to, heat absorbers, heat reflectors, filters, photovoltaic modules, electrochromic modules, and combinations thereof.

[0050] The intermediate layer 125 comprises a TPU that is substantially optically transparent and has sufficient adhesiveness to bond to various materials, such as glass, polycarbonate, acrylics, etc. In an exemplary embodiment, the TPU comprises an aliphatic TPU, preferably a polyether-type aliphatic TPU. The hardness of the polyether-type aliphatic TPU is in the range of about 60 Shore A to about 100 Shore A, or about 70 Shore A to about 85 Shore A.

[0051] Aliphatic TPU is a major compound with excellent optical transparency and typically does not decompose (i.e., yellow) when exposed to UV light. Furthermore, polyether-type aliphatic TPU has extremely strong adhesion and can adhere to many different materials, such as polycarbonate and acrylics. Therefore, the integral interlayer described in this application is similar to a double-sided adhesive film or tape with solar energy control properties, enabling users to bond or laminate many different materials, including polycarbonate, glass, and / or acrylics, to one or both sides of the tape.

[0052] The thickness of the intermediate layer 125 is preferably suitable for adhesion to the outer layers 110, 120, or is at least about 0.015 inches, preferably in the range of about 0.015 inches to about 0.100 inches. In an exemplary embodiment, the total thickness of the intermediate layer 125 is about 0.015 inches to about 0.05 inches, about 0.015 inches to about 0.04 inches, or about 0.02 inches to about 0.025 inches.

[0053] In some embodiments, the haze of the intermediate layer 125 may be less than about 3.5%, or less than about 2%, preferably less than or equal to about 1%. The light transmittance of the intermediate layer may be greater than about 30%, or greater than about 50%, preferably greater than about 70%, and more preferably at least about 73%. The ultraviolet-visible spectral transmittance (UV-VIS) of the TPU layer may be less than about 10%, less than about 5%, or less than or equal to about 1%.

[0054] In one embodiment, the intermediate layer 125 includes a first TPU layer and second TPU layers 130, 140, and a third inner TPU layer 150 with a coating 160 embedded within the first and second TPU layers 130, 140. The first and second layers 130, 140 preferably comprise aliphatic TPU as described above. Functional elements are disposed on the coating 160 such that the third TPU layer 150 provides a substrate for retaining the functional elements on the coating 160.

[0055] In an exemplary embodiment, the third TPU layer 150 comprises polycaprolactone-based TPU. Polycaprolactone-based TPU is harder than aliphatic TPU and is more suitable for applying coatings thereon. In an exemplary embodiment, the hardness of the third TPU layer is about 40 Shore D to about 85 Shore D, or about 55 Shore D to about 70 Shore D. However, polycaprolactone-based TPU is generally less optically transparent than aliphatic TPU (i.e., they have a higher yellowness index). Therefore, providing aliphatic TPU as the primary intermediate layer, including a thinner layer of polycaprolactone-based TPU, yields an intermediate layer with suitable adhesive and optical properties, while allowing functional elements or solar control functions to be placed therein. Furthermore, the relatively lightweight nature of aliphatic TPU (compared to other TPUs or other intermediate layer materials such as PVB) makes this laminate particularly suitable for applications requiring lightweight structures, such as electric vehicles.

[0056] In some embodiments, the selected TPU is flexible or moldable to manufacture deformable or flexural laminates with solar energy control properties. In this embodiment, the laminate can be used with curved glass, polycarbonate, etc., to manufacture, for example, bay windows, arched windows, domed windows, corner windows, pre-bent vehicle windows, curved bulletproof windows, etc.

[0057] A first layer 130 may be extruded onto a first surface of an inner TPU layer 150, and a second layer 140 may be extruded onto a second surface of the TPU layer 150 opposite to the first surface (or directly onto the coating 160). The first and second layers 130, 140 may be extruded individually or as part of a single process. In either process, the first and second TPU layers 130, 140 are fused together with the inner TPU layer 150 to form a single, monolithic TPU interlayer integrating internal solar control characteristics. In an exemplary embodiment, the thickness of each of the first and second layers 130, 140 may be approximately 0.005 to approximately 0.025 inches, preferably approximately 0.005 to approximately 0.015 inches, or approximately 0.01 inches.

[0058] The thickness of the inner TPU layer 150 is suitable for providing solar control characteristics thereon. In one embodiment, the thickness of the inner layer 150 is less than about 0.003 inches, or about 0.008 inches.

[0059] The coating 160 can be applied to the TPU layer 150 by any suitable method, such as drop casting, dip coating, optical deposition, vacuum deposition, electrospinning, electrospraying, layer-by-layer deposition, spin coating, etc. In an exemplary embodiment, the coating 160 is sputtered onto the layer 150. The thickness of the inner TPU layer 150 can be from about 0.00075 to about 0.0009 inches, preferably about 0.0008 inches.

[0060] The outer layers 110 and 120 comprise an optically transparent, fundamentally rigid material. Suitable materials for the outer layers 110 and 120 include, but are not limited to, glass, artificial glass, or any known glass alternative, such as polycarbonate, acrylic resin, polyester, polyether, and polyurethane. In one embodiment, the outer layers 110 and 120 comprise float glass, tempered glass, or chemically strengthened glass, such as borosilicate glass.

[0061] In another embodiment, the outer layers 110, 120 comprise polycarbonate. In this embodiment, the laminate may have sufficient impact resistance to be used, for example, as a bulletproof window.

[0062] In another embodiment, the outer layers 110, 120 comprise acrylics. In this embodiment, the laminating material may include a decorative film for application to windows, doors, walls, etc.

[0063] The intermediate layer 125 may include optoelectronic properties suitable for LGU100 applications. In one embodiment, the quantum yield of the intermediate layer 125 may be greater than about 50%. Quantum yield (Φ) is defined as the ratio of the number of emitted photons to the number of absorbed photons.

[0064] The intermediate layer 125 may include an tackifier to enhance the adhesion between the outer layers 110, 120 and the intermediate layer 125, and to prevent the adhesive from peeling off from the layers. Suitable tackifiers include, but are not limited to, organosilanes, organotitanates, zirconates, zirconium aluminates, alkyl phosphates, organometallic compounds, etc.

[0065] The composite laminate 100 is optically transparent. In some embodiments, the light transmittance of the laminate is at least about 30%, at least about 50%, or preferably at least 70%. The haze of the laminate 100 may be less than about 2%, less than or equal to about 1%, or preferably less than or equal to about 0.7%.

[0066] Now refer to Figure 2Another embodiment of the laminate 200 includes an optically transparent optical layer 210 and an adhesive intermediate layer 225 laminated to the optical layer 210. The intermediate layer 125 is an integral structure comprising thermoplastic polyurethane (TPU) having sufficient thickness to adhere to the outer layers 110, 120, preferably with a thickness of at least about 0.015 inches. One or more functional elements are included within or otherwise disposed therein the integral structure of the polymer intermediate layer 125.

[0067] The intermediate layer 225 comprises a TPU that is substantially optically transparent and has sufficient adhesive properties to bond to various materials, such as glass, polycarbonate, acrylic, etc. In an exemplary embodiment, the TPU comprises an aliphatic TPU, preferably a polyether-type aliphatic TPU.

[0068] In one embodiment, the intermediate layer 225 includes a first TPU layer and second TPU layers 230, 240, and a third inner polymer layer 250 with a coating 260 disposed within the first and second TPU layers 230, 240. Functional elements are disposed on the coating 260 such that the third TPU layer 250 provides a substrate for retaining the functional elements on the coating 160. In an exemplary embodiment, the third TPU layer 250 includes polycaprolactone-based TPU.

[0069] In some embodiments, coating 160 or 260 includes one or more optical elements, materials, and / or layers made of materials that allow visible light to pass through and reflect or absorb UV and / or IR light. For example, IR-blocking optical elements may be configured to reflect or absorb light with wavelengths from about 700 nm to 1 mm, preferably from about 700 nm to about 1400 nm (i.e., near-infrared wavelengths), more preferably from about 750 nm to about 1200 nm. In one embodiment, the optical element includes an IR-reflective coating. Materials suitable for reflecting light in the IR range include metals or metal-based coatings, such as double or triple silver coatings, liquid crystal materials that selectively transmit or scatter IR light, etc.

[0070] In another embodiment, the optical element includes an IR absorbing material, such as an IR absorbing dye, a copper salt composition (e.g., copper phosphonate), nanoparticles (e.g., zinc oxide, antimony tin oxide (ATO), lanthanum hexaboride (LaB), etc.), an infrared filter (e.g., blue glass), an intermediate layer film including infrared shielding fine particles, etc.

[0071] In yet another embodiment, the IR absorbing element includes IR absorbing particles, such as nanoparticles, dispersed in one of the TPU layers. In this embodiment, for example, the first TPU layer may include a UV blocking material, while the second TPU layer may include IR blocking particles.

[0072] In some embodiments, coating 160 or 260 may include optical elements, layers, or materials capable of reflecting or absorbing UV light. The UV-blocking optical elements preferably reflect or absorb light with wavelengths of about 10 to 410 nanometers, more preferably greater than about 380 nanometers, and even more preferably about 380 to 410 nanometers. The optical elements may include any material configured to reflect or absorb UV light, such as UV radiation absorbing, blocking, or shielding additives. Suitable UV radiation absorbing, blocking, or shielding additives for this disclosure include combinations of benzophenones, cinnamic acid derivatives, esters of benzoic acid, alicyclic acids, esters of terephthalic acid and isophthalic acid with resorcinol and phenol, pentamethylpiperidine derivatives, salicylates, benzotriazoles, cyanoacrylates, benzylenes, malonates, and oxalamides with nickel chelates and hindered amines.

[0073] Alternatively, UV-blocking optical elements may include a filter layer within the TPU layer. Suitable optical elements for use in this application include sheet polarizers, dichroic reflective filter materials, etc., to provide broadband UV radiation attenuation. For example, blue or green colored glass with significantly reduced transmittance in the UV portion, or blue or green colored polymer interlayers, coatings, or layers or polymer films of UV radiation attenuating coatings or varnishes may be suitable as UV-blocking materials.

[0074] In some embodiments, the optical element includes an IR blocking layer capable of reflecting or absorbing IR light and a separate UV blocking element capable of reflecting or absorbing UV light. The IR blocking element is preferably disposed between and in contact with the UV blocking element and one of the first and second thermoplastic polyurethane layers 130, 140. The IR blocking element is capable of reflecting or absorbing light with a wavelength of about 700 nm to about 1 mm, preferably about 700 nm to about 1400 nm, more preferably about 750 nm to about 1200 nm. The UV blocking element is preferably capable of reflecting or absorbing light with a wavelength of about 10 to 410 nm, preferably about 380 to 410 nm.

[0075] Alternatively, the optical element may comprise a single material that blocks both UV and IR light. Suitable materials for the optical layer in this embodiment may include a metallic coating, such as a double or triple silver layer. A more complete description of optical elements that absorb or reflect IR and UV light can be found in co-filed international application PCT / US2021 / 40300, entitled "Laminated Assembly Having Optical Layers or Materials," filed July 20, 2021, the full description of which is incorporated herein by reference for all purposes.

[0076] In some embodiments, coating 160 or 260 includes one or more light emitters. In an exemplary embodiment, the light emitter is a fluorophore, which is a fluorescent compound configured to re-emit light upon photoexcitation. A fluorophore typically comprises multiple combined aromatic groups, or a planar or cyclic molecule having multiple π bonds. In one embodiment, intermediate layers 150, 160 include multiple fluorophores finely dispersed within a polyurethane matrix.

[0077] The emitter can be configured to absorb most of the near-infrared (NIR) or UV photons passing through the intermediate layers 125 and 225. In one embodiment, the intermediate layers 125 and 225 comprise phosphorescent organic molecules or a mixture of various emitters (such as quantum dots or organic dyes) to reduce reabsorption loss and improve overall absorption efficiency across the entire spectrum. In one such embodiment, the structure of the emitter is selected from, but is not limited to, MX2. L2, AMX2L2, M6X12L2, A2M6X14 and A2M6X14 . The group consisting of L2, where M = W or Mo, X-Cl, Br or I, L = Cl, CH3CN, thiophenol, ethanethiol, H2O (hydrate), HCl and acetonitrile, and A = K, Na, tetrabutylammonium (TBA) and other ammonium salts. In another embodiment, the plurality of luminescent elements comprise quantum dots having a core / shell structure selected from, but not limited to, the group consisting of: CdSe / CdS, CdSe / ZnSe, CdSe / ZnS, CdSe / ZnTe, CdSe / CdTe, CdTe / CdSe, CdTe / CdS, CdTe / ZnSe, CdTe / ZnS, CdTe / ZnTe, CdS / ZnSe, CdS / ZnS, CdS / CdTe, CdS / CdSe, PbSe / PbS, PbS / PbSe, PbTe / PbS, PbS / PbTe, PbT e / PbSe, PbSe / PbTe, PbSe / CdSe, CdSe / PbTe, PbS / CdS, CdS / PbS, PbTe / CdTe, CdTe / PbTe, InAs / CdS, InSb / CdS, InP / CdS, InAs / CdSe, InSb / CdSe, InP / CdSe, InAs / ZnSe, InP / ZnSe, InSb / ZnSe, InAs / ZnS, InP / ZnS, InSb / ZnS, Ge / Si, Si / Ge, Sn / Si, Si / Sn, Ge / Sn or Sn / Ge.

[0078] In some embodiments, the laminate 100 or 200 may comprise an ionomer or a polymer consisting of repeating units of electrically neutral repeating units and ionized units covalently bonded to the polymer backbone as side-group portions. A certain molar percentage (e.g., 15% or less) is ionized. The ionomer may have unique physical properties, such as conductivity and viscosity.

[0079] In some embodiments, the laminate 100 or 200 may include photovoltaic, electrochromic, and / or other functionalities for conductivity. In one such embodiment, the laminate 100 includes a photovoltaic module within a coating 160. For example, quantum dots may be disposed within the coating 160. Another suitable alternative for quantum dots for energy generation is an organic photovoltaic (OPV) cell, which may be employed here. Organic photovoltaic technology has rapidly emerged due to its improved cell efficiency, good performance lifetime, and proven potential for roll-to-roll manufacturing using solution processing. OPV may be an attractive alternative because it offers absorbers of any color and enables the fabrication of highly efficient, transparent devices. Another advantage is the availability of a variety of organic materials for designing and synthesizing absorbers, acceptors, and interfaces. Organic photovoltaic cells can be applied via thin-film deposition, such as sputtering and pulsed laser deposition, to fabricate such thin-film OPVs for energy generation. For a more complete description of suitable photovoltaic modules, see co-filed, co-pending U.S. Provisional Patent Application No. 63 / 470,128 (“Functional Glass and Artificial Glass Laminates”), filed May 31, 2023, the full description of which is incorporated herein by reference for all purposes.

[0080] In some embodiments, the laminate 100 or 200 may include an electrochromic component (“EC”). The electrochromic component includes an ion-conducting intermediate layer film disposed between a first electrode layer and a second electrode layer. In some embodiments, a wire may connect a photovoltaic module to the electrochromic component, wherein the photovoltaic module supplies power to the electrochromic component. In other embodiments, the electrical connection may be a busbar, a conductive trace, or other form of electrical connection. In some embodiments, the electrochromic component is connected to a potential outside the window unit. Suitable electrochromic components can be found in the aforementioned patent application (“Functional Glass and Artificial Glass Laminates”) and the co-filed, co-pending international patent application PCT / US2021 / 63210 (“Optically Transparent Electrolyte Membrane”), filed on December 14, 2021, the full description of which is incorporated herein by reference for all purposes.

[0081] It should be understood that the intermediate layer, functional laminate, and insulated glass units (IGUs) described in this application can be integrated into freestanding window units without external wiring connections, thereby improving the energy efficiency of buildings or vehicles. For example, this laminate can be used in integrated dynamic glass window products, suitable for use as windows in buildings, residences, housing structures, transportation and construction equipment (such as trucks, tractors, and buses), automobiles, aviation equipment (such as airplanes and helicopters), protective storage containers (such as glass sealing boxes), optical lenses in electronic devices, and other such applications utilizing glass or glass laminates with performance layers.

[0082] This window can integrate electrochromic components and / or photovoltaic modules to control light transmittance and provide power for the unit's electrochromic features. The unit is independent and does not require connection to an external power source. Automatic control of light transmittance and other features can be included, while the unit possesses the optical properties and aesthetics required for a window.

[0083] The interlayer and laminating materials described in this application can be integrated into an insulated glass unit (“IGU”). The integrated dynamic glazing product includes an IGU having an electrochromic module and a photovoltaic module separated and held within a frame by a gap. The electrochromic module includes a first electrode layer, a second electrode layer, and an ion-conducting interlayer film disposed between the first and second electrode layers. Applying a potential to this module causes a change in its color and light transmittance. The electrochromic module can adjust the light transmittance to a desired level. This can reduce cooling requirements in buildings or vehicles while allowing some light to enter. However, changing the state of the electrochromic module requires a power source.

[0084] The photovoltaic module may have a series of light-emitting solar concentrators (LSCs) disposed in a polymer interlayer, which may be extruded and assembled into a laminate. For example, quantum dots may be disposed in thermoplastic polyurethane (“TPU”), ethylene-vinyl acetate copolymer (“EVA”), or polymethyl methacrylate (“PMMA”). In some embodiments, this layer is formed by single-screw or twin-screw extrusion, coating, casting, UV curing, or other methods. Wires connect the photovoltaic module to the electrochromic module, making the IGU a standalone unit where the photovoltaic module powers the electrochromic module. In other embodiments, the power to the electrochromic module is provided by an external power source. The IGU may include a transceiver for wireless communication with an external control unit or computer to automatically control the electrochromic aspects of the IGU. For example, the electrochromic feature may be used to block light transmittance at different times of day and adjust according to seasonal variations or user-preferred schemes. The IGU may communicate with a home control system via the transceiver and become part of a system that controls heating, ventilation, and cooling, such as a smart thermostat and other known systems, such as Internet of Things (IoT) devices. Similar systems and devices can also be integrated into vehicles.

[0085] In some implementations, LSCs are colloidal semiconductor nanocrystals, also known as quantum dots, typically less than 20 nanometers in diameter. Natural light excites electrons in the quantum dots, directing the energy to the sides of the layer. Photovoltaic cells convert this energy into electrical energy. For example, photovoltaic cells are positioned along the long side of the layer in close contact with it, or in areas near the transparent portion of a window.

[0086] Example 1 The applicant prepared and evaluated samples of the aforementioned interlayer and laminate materials. The percentage of visible light transmittance (VLT%), haze percentage, and percentage of ultraviolet-visible spectral transmittance (UV-VIS) at approximately 365 nm were tested for each sample. The test results are shown in Table 1 below. Sample 1 is a single internal TPU layer with a coating integrating solar energy control properties. Sample 2 is a laminate material comprising an internal TPU layer with an Argotec™ HP8000 aliphatic TPU interlayer extruded onto the film through two channels, and a first and second glass outer layers. Sample 3 is a laminate material comprising an internal TPU layer with an Argotec™ ST-6050 aliphatic TPU interlayer extruded onto the film through two channels, and a first and second glass outer layers.

[0087] Table 1 As shown in Table 1, the VLT of the laminates (samples 2 and 3) is approximately 73%, the haze percentage is approximately 1 and 1.2, and the UV-VIS% at 365 nm is approximately 0.

[0088] Figure 3 The figure shows the percentage of transmittance of the sample at different wavelengths (in nanometers). As shown, the transmittance of UV light (i.e., 100 to 380 nm) is extremely low, while the transmittance of visible light (i.e., 400 to 700 nm) is as high as 80% at lower wavelengths and higher frequencies, and then gradually decreases at higher wavelengths in the visible light range (dropping to about 55-60% at 700 nm, where the IR range begins).

[0089] Example 2 The percentage of visible light transmittance (VLT%), haze percentage, yellowness index (YI), CIELAB color space coordinates (L, a*, and b*), and percentage of UV-Vis spectral transmittance (UV-VIS) at approximately 380 nm and 400 nm were evaluated for each sample. Samples 4A and 4B consist of two extruded 635-micron Argotec™ HP8000 aliphatic TPU layers without an inner TPU layer with a coating integrating solar control properties. Samples 5A and 5B consist of an inner TPU layer with a coating integrating solar control properties, which is further encapsulated by extruding two 635-micron Argotec™ HP8000 aliphatic TPU layers on both sides. Samples 6A and 6B comprise an internal TPU layer with a coating integrating solar control properties, further encapsulated by extruding a 635-micron Argotec™ HP8000 aliphatic TPU layer on one side and another 635-micron Argotec™ HP8000 aliphatic TPU layer including an enhanced UV blocker on the other side. Finally, samples 7A and 7B comprise an internal TPU layer with a coating integrating solar control properties, further encapsulated by extruding two 635-micron Argotec™ HP8000 aliphatic TPU layers including an enhanced UV blocker on both sides. Each intermediate layer is laminated between two sheets of clear borosilicate glass using a standard vacuum bag autoclave lamination process.

[0090] The evaluation results for samples 4A-7B are shown in Table 2 below. As shown, samples 4-7 all exhibit extremely low light transmittance at 380 nm, and samples 6 and 7 also exhibit extremely low light transmittance even at 400 nm due to enhanced UV blocking properties. All samples have light transmittance exceeding 85%, and haze far below the 3% required for optical applications. A comparison of sample 5 with sample 4 shows that the sample including an internal third TPU layer between the first and second aliphatic TPU layers, along with a coating integrating solar energy control properties, only results in a slight increase in haze and YI. A comparison of samples 6 and 7 with sample 5 shows that the integrated enhanced UV blocking capability leads to an increase in YI, but has no effect on haze or light transmittance.

[0091] Table 2 Figure 4 The light transmittance spectra of samples 4A, 5A, and 6A are shown. At all test wavelengths, the light transmittance of samples 5A and 6A was lower than that of sample 4A. However, the decrease in light transmittance was more significant in the near-infrared region of 800–2500 nm. This decrease is due to the solar control coating on the core TPU layer. Sample 4A does not contain this solar control coating, and therefore is less effective at blocking near-infrared light, which primarily contributes to increased heat.

[0092] Figure 5 The UV region (280–400 nm) portion of the spectrum is shown to demonstrate the effect of the enhanced UV blocker. While samples 4A and 5A show increased light transmittance above 390 nm, sample 6A blocks UV light up to 400 nm. As can be seen from Figure 7, sample 6A combines enhanced UV blocking capability without compromising the infrared shielding properties imparted by the core TPU layer containing a coating with solar energy control properties. The results shown in Figures 7 and 8 were obtained on a Cary 5000 UV-Vis-NIR spectrophotometer.

[0093] Although this application has described these materials and products formed from these materials in detail according to certain preferred embodiments, many modifications and alterations can be made thereto by those skilled in the art. Therefore, the foregoing description should not be construed as limiting, but rather as including the obvious variations described above, and is limited only by the spirit and scope of the appended claims.

[0094] For example, in one aspect, a first embodiment is an intermediate layer comprising an adhesive film having an integral structure comprising thermoplastic polyurethane (TPU), the film also comprising one or more functional elements within its integral structure. The thickness of the film is at least about 0.015 inches.

[0095] The second embodiment is the first embodiment, wherein the thickness of the film is about 0.015 inches to about 0.100 inches.

[0096] The third implementation is any combination of the first two implementations, wherein the TPU includes aliphatic TPU.

[0097] The fourth embodiment is any combination of the first three embodiments, wherein the aliphatic TPU includes polyether aliphatic TPU.

[0098] The fifth embodiment is any combination of the first four embodiments, wherein the hardness of the polyether-type aliphatic TPU is from about 70 Shore A to about 85 Shore A.

[0099] The sixth implementation is any combination of the first five implementations, wherein the monolithic structure includes a first upper TPU layer and a second lower TPU layer.

[0100] The seventh embodiment is any combination of the first six embodiments, wherein the thickness of the first layer and the second layer is approximately 0.005 inches.

[0101] The eighth embodiment is any combination of the first seven embodiments, wherein the monolithic structure further includes a third TPU layer disposed between the first and second layers.

[0102] The ninth embodiment is any combination of the first eight embodiments, wherein the third TPU layer comprises an aliphatic TPU.

[0103] The tenth embodiment is any combination of the first nine embodiments, wherein the aliphatic TPU layer is polycaprolactone-based TPU.

[0104] The eleventh embodiment is any combination of the first ten embodiments, wherein the hardness of the polycaprolactone-based TPU is about 55 Shore D to about 70 Shore D.

[0105] The twelfth embodiment is any combination of the preceding eleven embodiments, wherein the functional elements include one or more of the following: a light emitter, a solar energy control element, an ionomer, a UV absorber, a UV reflector, an IR absorber, an IR reflector, and combinations thereof.

[0106] The thirteenth embodiment is any combination of the preceding twelve embodiments, wherein the solar control element includes one or more of the following: heat absorber, heat reflector, filter, photovoltaic module, electrochromic module, and combinations thereof.

[0107] The fourteenth embodiment is any combination of the preceding thirteen embodiments, wherein the luminescent body includes phosphorescent organic molecules, quantum dots, organic dyes, or combinations thereof.

[0108] The fifteenth embodiment is any combination of the preceding fourteen embodiments, wherein one or more functional elements are disposed on the coating and the coating is adhered to the third TPU layer.

[0109] The sixteenth embodiment is any combination of the preceding fifteen embodiments, wherein the film is sputtered onto the inner polymer layer.

[0110] The seventeenth embodiment is any combination of the first sixteen embodiments, wherein the thickness of the coating and the third TPU layer is less than about 0.003 inches.

[0111] The eighteenth embodiment is any combination of the preceding seventeen embodiments, wherein the TPU layer is substantially optically transparent.

[0112] The nineteenth embodiment is any combination of the preceding eighteen embodiments, wherein one or more outer layers comprise a material selected from glass, artificial glass, polycarbonate, acrylic, polyester, polyether, and polyurethane.

[0113] In another aspect, a laminate material comprising any combination of the first nineteen embodiments is provided.

[0114] In another aspect, a window is provided that includes any combination of the first nineteen embodiments.

[0115] In another aspect, a decorative film comprising any combination of the first nineteen embodiments is provided.

[0116] In another aspect, a laminated material includes a first optically transparent layer and a second layer adhered to the first layer, the film having an integral structure comprising thermoplastic polyurethane (TPU), the second layer also including one or more functional elements within its integral structure, wherein the thickness of the second layer is at least about 0.015 inches.

[0117] The second embodiment is the first embodiment, and it further includes a third optically transparent layer, wherein the second layer is adhered to the third layer.

[0118] The third implementation is any combination of the first two implementations, wherein the second layer is disposed between the first layer and the third layer.

[0119] The fourth embodiment is any combination of the first three embodiments, wherein the first layer comprises a material selected from glass, artificial glass, polycarbonate, acrylic, polyester, polyether and polyurethane.

[0120] The fifth embodiment is any combination of the first four embodiments, wherein the first layer comprises a material selected from glass, polycarbonate and acrylic.

[0121] The sixth implementation is any combination of the first five implementations, wherein the TPU includes aliphatic TPU.

[0122] The seventh embodiment is any combination of the first six embodiments, wherein the aliphatic TPU includes polyether aliphatic TPU.

[0123] The eighth embodiment is any combination of the first seven embodiments, wherein the monolithic structure includes a first upper TPU layer and a second lower TPU layer.

[0124] The ninth embodiment is any combination of the first eight embodiments, wherein the thickness of the first layer and the second layer is approximately 0.005 inches.

[0125] The tenth embodiment is any combination of the preceding nine embodiments, wherein the integral structure further includes a third TPU layer disposed between the first layer and the second layer, wherein the third TPU layer comprises polycaprolactone.

[0126] The eleventh embodiment is any combination of the preceding ten embodiments, wherein the functional elements include one or more of the following: a light emitter, a solar energy control element, a UV absorber, a UV reflector, an IR absorber, an IR reflector, and combinations thereof.

[0127] The twelfth embodiment is any combination of the preceding eleven embodiments, wherein the solar control element includes one or more of the following: a heat absorber, a heat reflector, a filter, a photovoltaic module, an electrochromic module, and combinations thereof.

[0128] The thirteenth embodiment is any combination of the first twelve embodiments, wherein the luminescent body includes phosphorescent organic molecules, quantum dots, organic dyes, or combinations thereof.

[0129] The fourteenth embodiment is any combination of the preceding thirteen embodiments, wherein one or more functional elements are disposed on the coating, wherein the coating is adhered to the third TPU layer.

[0130] The fifteenth embodiment is any combination of the first fourteen embodiments, wherein the coating is sputtered onto the third TPU layer.

[0131] The sixteenth embodiment is any combination of the first fifteen embodiments, wherein the thickness of the coating and the third TPU layer is less than about 0.003 inches.

[0132] The seventeenth embodiment is any combination of the preceding sixteen embodiments, wherein the first layer comprises glass and the functional elements comprise solar control elements selected from heat absorbers, heat reflectors, filters, photovoltaic modules, electrochromic modules, and combinations thereof.

[0133] The eighteenth embodiment is any combination of the preceding seventeen embodiments, wherein the first layer comprises polycarbonate and the functional elements comprise solar control elements selected from heat absorbers, heat reflectors, filters, photovoltaic modules, electrochromic modules, and combinations thereof.

[0134] The nineteenth embodiment is any combination of the first eighteen embodiments, wherein the laminate is bulletproof.

[0135] The twentieth embodiment is any combination of the preceding nineteen embodiments, wherein the first layer comprises acrylic resins and the functional elements comprise solar control elements selected from heat absorbers, heat reflectors, filters, photovoltaic modules, electrochromic modules, and combinations thereof.

[0136] The twenty-first embodiment is any combination of the first twenty embodiments, wherein the first layer and the adhesive film are non-linear.

[0137] In another aspect, a window is provided that includes any of the preceding twenty-one embodiments.

[0138] In another aspect, a solar-powered controlled window is provided, comprising any of the preceding twenty-one embodiments, wherein the first layer comprises glass.

[0139] In another aspect, a panoramic roof for automobiles is provided, which includes any of the preceding twenty-one embodiments.

[0140] In another aspect, an impact-resistant window is provided, comprising any of the preceding twenty-one embodiments, wherein the first layer comprises polycarbonate.

[0141] In another aspect, a decorative layer is provided, comprising any of the preceding twenty-one embodiments, wherein the first layer comprises an acrylic layer.

Claims

1. An intermediate layer, comprising: An adhesive film having an integral structure comprising thermoplastic polyurethane (TPU), the film further comprising one or more functional elements within its integral structure; The thickness of the membrane is at least about 0.015 inches.

2. The intermediate layer of claim 1, wherein the thickness of the film is from about 0.015 inches to about 0.100 inches.

3. The intermediate layer of claim 1, wherein the TPU comprises aliphatic TPU.

4. The intermediate layer of claim 3, wherein the aliphatic TPU comprises a polyether-type aliphatic TPU.

5. The intermediate layer of claim 4, wherein the hardness of the polyether-type aliphatic TPU is in the range of about 70 Shore A to about 85 Shore A.

6. The intermediate layer of claim 1, wherein the integral structure comprises a first upper TPU layer and a second lower TPU layer.

7. The intermediate layer of claim 6, wherein the thickness of the first layer and the second layer is at least about 0.005 inches.

8. The intermediate layer of claim 6, wherein the integral structure further comprises a third TPU layer disposed between the first TPU layer and the second TPU layer.

9. The intermediate layer of claim 8, wherein the third TPU layer comprises aliphatic TPU.

10. The intermediate layer of claim 9, wherein the aliphatic TPU is a polycaprolactone-based TPU.

11. The intermediate layer of claim 10, wherein the polycaprolactone-based TPU has a hardness of about 55 Shore D to about 70 Shore D.

12. The intermediate layer of claim 1, wherein the functional element is selected from light emitters, solar energy control elements, ionomers, UV absorbers, UV reflectors, IR absorbers, IR reflectors, and combinations thereof.

13. The intermediate layer of claim 12, wherein the solar energy control element is selected from heat absorbers, heat reflectors, filters, photovoltaic modules, electrochromic modules, and combinations thereof.

14. The intermediate layer of claim 12, wherein the light emitter comprises phosphorescent organic molecules, quantum dots, organic dyes, or combinations thereof.

15. The intermediate layer of claim 8, wherein one or more functional elements are disposed on the coating, wherein the coating is adhered to the third TPU layer.

16. The intermediate layer of claim 15, wherein the coating is sputtered onto the third TPU layer.

17. The intermediate layer of claim 15, wherein the thickness of the coating and the third TPU layer is less than about 0.003 inches.

18. The intermediate layer of claim 1, wherein the adhesive film is substantially optically transparent.

19. The intermediate layer of claim 1, wherein the visible light transmittance percentage of the intermediate layer is at least about 85%.

20. The intermediate layer of claim 1, wherein the percentage haze of the intermediate layer is less than about 1.7%.

21. The intermediate layer of claim 1, wherein the yellowness index (YI) of the intermediate layer is less than about 5.

0.

22. The intermediate layer of claim 1, wherein the light transmittance of the intermediate layer at 380 nm is less than about 0.04%.

23. The intermediate layer of claim 1 further comprises an optical material on the TPU, the optical material being configured to reflect or absorb UV light.

24. The intermediate layer of claim 23, wherein the light transmittance of the intermediate layer at 400 nm is less than about 40%.

25. The intermediate layer of claim 24, wherein the light transmittance at 400 nm is less than about 10%.

26. The intermediate layer of claim 24, wherein the light transmittance at 400 nm is less than about 2%.

27. A laminated material comprising the intermediate layer as described in claim 1.

28. The laminate of claim 27 further comprises one or more outer layers bonded to the intermediate layer, wherein the one or more outer layers comprise a material selected from glass, artificial glass, polycarbonate, acrylic, polyester, polyether, and polyurethane.

29. A window comprising the laminated material of claim 27.

30. A decorative layer comprising the laminate of claim 27.

31. A laminated material, comprising: First optically transparent layer; as well as A second layer is adhered to the first layer, the second layer comprising an integral structure comprising thermoplastic polyurethane (TPU), and the second layer further comprising one or more functional elements within its integral structure; The thickness of the second layer is at least about 0.015 inches.

32. The laminate of claim 31 further comprises a third layer, wherein the third layer is optically transparent, and the second layer is adhered to the third layer.

33. The laminate of claim 32, wherein the second layer is disposed between the first layer and the third layer.

34. The laminate of claim 31, wherein the first layer comprises a material selected from glass, artificial glass, polycarbonate, acrylic, polyester, polyether and polyurethane.

35. The laminate of claim 31, wherein the first layer comprises a material selected from glass, polycarbonate and acrylic.

36. The laminate of claim 31, wherein the third layer comprises a material selected from glass, polycarbonate and acrylic.

37. The laminated material of claim 31, wherein the monolithic structure comprises a first upper TPU layer and a second lower TPU layer.

38. The laminate of claim 37, wherein the thickness of the first TPU layer and the second TPU layer is at least about 0.005 inches.

39. The laminated material of claim 37, wherein the monolithic structure further comprises a third TPU layer disposed between the first layer and the second layer.

40. The laminate of claim 39, wherein one or more functional elements are disposed on the coating, wherein the coating is adhered to the third TPU layer.

41. The laminate of claim 40, wherein the coating is sputtered onto the third TPU layer.

42. The laminate of claim 40, wherein the thickness of the coating and the third TPU layer is less than about 0.003 inches.

43. The laminate of claim 31, wherein the first layer comprises glass, and the functional element comprises a solar control element selected from heat absorbers, heat reflectors, filters, photovoltaic modules, electrochromic modules, and combinations thereof.

44. The laminate of claim 31, wherein the first layer comprises polycarbonate, and the functional element comprises a solar control element selected from heat absorbers, heat reflectors, filters, photovoltaic modules, electrochromic modules, and combinations thereof.

45. The laminate of claim 44, wherein the laminate is bulletproof.

46. ​​The laminate of claim 31, wherein the first layer comprises an acrylic material, and the functional element comprises a solar control element selected from heat absorbers, heat reflectors, filters, photovoltaic modules, electrochromic modules, and combinations thereof.

47. The laminate of claim 31, wherein the first layer and the adhesive film are non-linear.

48. A window comprising the laminated material of claim 31.

49. A panoramic roof for automobiles, comprising the laminated material of claim 31.

50. A solar-controlled window comprising the laminate of claim 31, wherein the first layer comprises glass.

51. An impact-resistant window comprising the laminate of claim 31, wherein the first layer comprises polycarbonate.

52. A decorative layer comprising the laminate of claim 31, wherein the first layer comprises an acrylic material.

53. An intermediate layer, comprising: First thermoplastic polyurethane (TPU) layer, The second TPU layer, and A third polymer layer is disposed between the first polymer layer and the second polymer layer, the third polymer layer comprising one or more functional elements.

54. The intermediate layer of claim 53, wherein the third polymer layer comprises TPU.

55. The intermediate layer of claim 53, further comprising a coating on the third polymer layer, wherein one or more functional elements are disposed on the coating.

56. The intermediate layer of claim 55, wherein the coating is sputtered onto the third TPU layer.

57. The laminate of claim 55, wherein the thickness of the coating and the third TPU layer is less than about 0.003 inches.

58. The laminate of claim 53 further comprises an optical material on the first TPU layer, wherein the optical material is configured to reflect or absorb UV light.

59. The intermediate layer of claim 53 further comprises a second optical material on the second TPU layer, wherein the second optical material is configured to reflect or absorb UV light.

60. The intermediate layer of claim 53, wherein the first, second, and third layers form an integral structure having a thickness of at least about 0.015 inches.

61. The intermediate layer of claim 60, wherein the thickness of said structure is from about 0.015 inches to about 0.100 inches.

62. The intermediate layer of claim 53, wherein the thickness of each of the first TPU layer and the second TPU layer is at least about 0.005 inches.

63. The intermediate layer of claim 53, wherein the functional element is selected from light emitters, solar energy control elements, ionomers, UV absorbers, UV reflectors, IR absorbers, IR reflectors, and combinations thereof.

64. The intermediate layer of claim 53, wherein the visible light transmittance percentage of the intermediate layer is at least about 85%.

65. The intermediate layer of claim 53, wherein the percentage haze of the intermediate layer is less than about 1.7%.

66. The intermediate layer of claim 53, wherein the yellowness index (YI) of the intermediate layer is at least about 93.

67. The intermediate layer of claim 53, wherein the light transmittance of the intermediate layer at 380 nm is less than about 0.04%.

68. The intermediate layer of claim 67, wherein the light transmittance of the intermediate layer at 400 nm is less than about 40%.

69. The intermediate layer of claim 68, wherein the light transmittance at 400 nm is less than about 10%.

70. The intermediate layer of claim 68, wherein the light transmittance at 400 nm is less than about 2%.

71. A laminated material comprising the intermediate layer as described in claim 53.

72. The laminate of claim 71 further comprises one or more outer layers bonded to the intermediate layer, wherein the one or more outer layers comprise a material selected from glass, artificial glass, polycarbonate, acrylic, polyester, polyether, and polyurethane.

73. A window comprising the laminated material of claim 71.

74. A decorative layer comprising the laminate of claim 73.

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