Stacked structures use sunlight to control the intermediate layer

Abstract

A functional interlayer is provided for incorporation into a laminate structure. The functional interlayer may provide solar control properties to the laminate structure. The laminate structure may be part of a window unit.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 412,102, filed September 30, 2022, the entire disclosure of which is incorporated herein by reference for all purposes.

[0002] This specification relates generally to laminates having functional properties such as solar control properties, functional interlayers for incorporation into the laminates that provide such solar control properties, and various structures including window units formed from laminates having such solar control interlayers. [Background technology]

[0003] Solar control films are used in vehicle and residential windows to improve energy efficiency. In residential or commercial buildings, these solar control films help control heat gain from sunlight through windows. This has the effect of reducing the load on heating, ventilation, and cooling systems, resulting in improved energy efficiency and reduced utility bills. In vehicles such as automobiles, reducing heat gain from windows and sunlight improves fuel efficiency. Solar control layers allow visible light to pass through but reject energy from sunlight. Some solar control films reject energy from the infrared and / or near-infrared range. A laminated glass unit (LGU) is a laminated assembly that includes one or more interlayers interposed between transparent, rigid plies. The rigid plies can be glass or other well-known alternatives, such as polycarbonate, acrylic, polyester, and rigid, transparent polyurethane. The interlayers join adjacent rigid plies to form a unitary laminated assembly and can be thermoplastic materials such as polyvinyl formal, polyvinyl butyral, polyvinyl isobutyral, silicone, or ethylene vinyl acetate (EVA).

[0004] These laminates or LGUs may include glass and / or polymer panes that provide structural strength, impact resistance, hurricane resistance, and bullet resistance. The laminates may also include sound-attenuating insulation to reduce noise penetration in vehicles or buildings. Preferably, the laminates have high optical clarity, low haze, long-term thermal stability, and long-term weatherability. Some known solar control films have a transparent, flexible polymer substrate onto which a thin layer of reflective metal is deposited by vapor deposition or sputter deposition. The flexible polymer substrate is susceptible to chemical attack, mechanical abrasion, and lacks structural support. The films are typically formed on a polyethylene terephthalate (PET) or polyethylene naphthalate (PEN) substrate. The films are incorporated into multilayer laminates with additional layers to provide hard protective layers, abrasion-resistant coatings, impact resistance, and other desirable functions. The films may have a pressure-sensitive adhesive (PSA) coating for adhesion to glass panes and a release liner that is removed and discarded before subsequent use.

[0005] The interlayer used in the laminate must have excellent adhesion to the substrate as well as the rigid skin of the window. Additionally, the interlayer must have optical clarity, durability, and adequate thermal and mechanical properties. The interlayer desirably has structural strength and load-bearing capacity in case the rigid skin is damaged by crime, natural disasters, weather, etc. The interlayer must accommodate the different expansion rates of the different layers of the laminate and have excellent optical clarity and stability in addition to impact resistance and good adhesion. There is a need for improved solar control interlayers that address the above-mentioned challenges, and more specifically, there is a need for interlayers that reduce the need for additional layers such as carrier layers and release liners, provide structural support, and / or provide other functional layers that may eliminate laminate and / or subcomponent formation steps for window units. Summary of the Invention

[0006] Described herein are functional interlayers for incorporation into laminate structures that address the above-mentioned challenges. The functional interlayers can provide solar control properties to the laminate structures. The laminate structures can be part of a window unit. According to one aspect, an interlayer subcomponent is provided. The interlayer subcomponent can include a carrier layer and at least one thermoplastic polyurethane layer disposed on a surface thereof. The at least one thermoplastic polyurethane layer can be adhesive when heated. The carrier layer can be a solar control layer. The carrier layer can be an electrochromic assembly, an infrared absorbing layer, or an infrared reflective layer.

[0007] The thermoplastic polyurethane may be an optical intermediate layer formed by extrusion. In some embodiments, a first thermoplastic polyurethane layer is disposed on a first surface of a carrier layer, and a second thermoplastic polyurethane layer is disposed on a second surface of the carrier layer, the second surface being opposite the first surface. The first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer may be adhesive when heated. The first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer may have the same thickness. The first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer may have different thicknesses.

[0008] In certain embodiments, the first thermoplastic polyurethane layer, the second thermoplastic polyurethane layer, or both thermoplastic polyurethane layers may be wedge-shaped, and thus the subcomponent may form part of a head-up display (HUD) window unit. In some embodiments, a first thermoplastic polyurethane layer can be disposed on a first surface of the carrier layer, and a second layer can be disposed on a second surface opposite the first surface. The second layer can be selected from the group consisting of polyvinyl butyral, polymethyl methacrylate, ethylene vinyl acetate, and polycarbonate. A second thermoplastic polyurethane layer can be disposed on the second layer.

[0009] In some embodiments, a first thermoplastic polyurethane layer is disposed on a first surface of the carrier layer and a layer providing acoustic attenuation is disposed on a second surface of the carrier layer, hi some embodiments, a first thermoplastic polyurethane layer is disposed on a first surface of the carrier layer and a layer providing impact resistance is disposed on a second surface of the carrier layer. In some embodiments, a first thermoplastic polyurethane layer may be disposed on the second side of the carrier layer, and a photovoltaic assembly may be disposed on the first side of the carrier layer. In some embodiments, the first side may be the side facing outward from the window unit. The photovoltaic assembly may include a polymer layer having quantum dots. In some embodiments, the photovoltaic cells may be arranged along an edge of the carrier layer. In some embodiments, when the photovoltaic cells are used in a window unit for a building, they may be disposed on one or more areas of the layer not relied upon for transparency. In some embodiments, a first thermoplastic polyurethane layer can be disposed on a first surface of a carrier layer, and an electrochromic assembly can be disposed on a second surface of the carrier layer. The electrochromic assembly can include a transparent electrode, a transparent ion-conducting polymer electrolyte film, and a second transparent electrode on the second surface of the carrier layer to complete the cell. The electrochromic coating can be deposited on either of the two transparent electrodes.

[0010] In some embodiments, a first thermoplastic polyurethane layer can be disposed on a first surface of the carrier layer and a layer of polyvinyl butyral can be disposed on a second surface of the carrier layer. In some embodiments, a first thermoplastic polyurethane layer can be disposed on a first surface of the carrier layer and a layer of poly(ethylene-co-vinyl acetate) can be disposed on a second surface of the carrier layer.

[0011] According to another aspect, a window unit for a vehicle or building can have an interlayer subcomponent comprising a carrier layer and at least one thermoplastic polyurethane layer thereon, the at least one thermoplastic polyurethane layer being adhesive when heated, the carrier layer being a solar control layer, and the interlayer subcomponent being disposed between a first rigid sheet and a second rigid sheet. In some embodiments, at least one of the first rigid sheet and the second rigid sheet is a layer of glass. In some embodiments, at least one of the first rigid sheet and the second rigid sheet is a layer of polymer. The window unit may further comprise an electromagnetic shield, a low emissivity layer, an electrochromic assembly, and / or a photovoltaic assembly.

[0012] According to a further aspect, a method of forming an interlayer subcomponent may be provided, the method may include providing a carrier layer and extruding a thermoplastic polyurethane layer onto one side of the carrier layer, the thermoplastic polyurethane layer being adhesive when heated, and the carrier layer being a solar control layer. The solar control layer may be selected from an electrochromic assembly, an infrared reflective layer, an infrared absorbing layer. In some embodiments, the method can further include extruding a first thermoplastic polyurethane layer onto a first side of the carrier layer and extruding a second thermoplastic polyurethane layer onto a second side of the carrier layer, where the first side can be opposite the second side. A first thermoplastic polyurethane layer can be extruded onto a first surface of the carrier layer in a first pass, and a second thermoplastic polyurethane layer can be extruded onto a second surface of the carrier layer in a second pass, and the first and second passes can be performed in the same extruder. In some embodiments, the method may further include collecting the intermediate layer subcomponent into a roll.

[0013] In some embodiments, a first thermoplastic polyurethane layer is extruded onto a first side of the carrier layer, further comprising extruding a second layer onto a second side of the carrier layer, the first side being opposite the second side, and the second layer being 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). The method may further include laminating a first rigid sheet and a second rigid sheet to the intermediate layer subcomponent, wherein the intermediate layer subcomponent is disposed between the first rigid sheet and the second rigid sheet. In some embodiments, at least one of the first rigid sheet and the second rigid sheet can be a sheet of glass. In some embodiments, at least one of the first rigid sheet and the second rigid sheet can be a rigid sheet of polymer. In some embodiments, the first and second thermoplastic polyurethane layers may be coextruded.

[0014] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present disclosure. Additional features of the present disclosure will be set forth in part in the description that follows, or may be learned by practice of the present disclosure. 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. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a perspective view of a solar control interlayer subcomponent according to an exemplary embodiment. [Figure 2] FIG. 2 is a cross-sectional view of the middle layer subcomponent of FIG. [Figure 3] FIG. 3 is a cross-sectional view of a window unit laminate having an interlayer subcomponent according to an exemplary embodiment. [Figure 4] FIG. 4 is a cross-sectional view of a middle layer subcomponent according to an exemplary embodiment. [Figure 5] FIG. 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. [Figure 6] FIG. 6 is a schematic diagram of an exemplary embodiment of a system for applying a coating to the second side of a solar control layer. [Figure 7] FIG. 7 is a perspective view of an exemplary embodiment of a window unit. DETAILED DESCRIPTION OF THE INVENTION

[0016] This description and the accompanying drawings illustrate exemplary embodiments and should not be construed as limiting, with the claims, including equivalents, defining the scope of this specification. Various mechanical, configurational, structural, and operational changes may be made without departing from the scope of this specification and the claims, including equivalents. In some instances, well-known structures and techniques have not been shown or described in detail to avoid obscuring the description. The same numbers in two or more figures represent the same or similar elements. Furthermore, elements and related aspects described in detail with reference to one embodiment may, to the extent practical, be included in other embodiments not specifically shown or described. For example, an element may be described in detail with reference to a first embodiment but not with reference to a second embodiment, and yet the element may be claimed as included in the second embodiment. Furthermore, the illustrations herein are for illustrative purposes only and do not necessarily reflect the actual shape, size, or dimensions of the system or illustrated components.

[0017] It should be noted that, as used in this specification and the appended claims, the singular forms "a," "an," "the," and the use of words in the singular include plural referents unless expressly and clearly limited to one referent. As used herein, the term "include" and its grammatical variations are intended to be non-limiting, and the enumeration of items in a list does not exclude other similar items that may be substituted for or added to the listed items.

[0018] Described herein are interlayer subcomponents for laminating additional layers to form a laminate or laminated structure, such as a laminated glass unit (LGU). The interlayer subcomponent can have a carrier layer with one or more polymer layers that become adhesive when heated. In some embodiments, the carrier layer can be a solar control layer, including a variable transmittance solar control layer, such as an electrochromic assembly, or a fixed transmittance solar control layer, such as an infrared-absorbing or infrared-reflecting layer. The interlayer subcomponent can include a photovoltaic assembly with a low-emissivity layer, quantum dots, organic photovoltaic cells, or other solar concentrators, such as luminescent solar concentrators (LSCs), an electromagnetic shielding layer, or other functional layers. The interlayer subcomponent can have polymer layers on two opposing sides that become adhesive when heated, making the subcomponent ready for lamination to other layers. The interlayer subcomponent is provided on a roll, and for lamination to other layers, the adhesive is part of the interlayer subcomponent and the functional solar control layer is the carrier; no additional carrier is required.

[0019] In some embodiments, the interlayer subcomponent can have functional properties, such as solar control properties. An exemplary embodiment of an interlayer subcomponent having such solar control properties is shown in FIGS. 1 and 2. The interlayer subcomponent 10 can have a solar control layer 12 and at least one polymer layer 14 thereon. The polymer layer 14 can be a thermoplastic polyurethane (TPU), which can become adhesive when heated. Other suitable polymer materials for the polymer layer 14 include, for example, polyvinyl formal, polyvinyl butyral (PVB), polyvinyl isobutyral, silicone, and ethylene vinyl acetate (EVA). Examples of solar control layers are described below.

[0020] In some embodiments, the interlayer subcomponent 10 may be laminated in an autoclave with a layer of glass or an optically clear rigid polymer sheet, such as polycarbonate, to form a window unit. Other rigid polymer materials, such as acrylic, polyacrylate, polymethyl methacrylate, cellulose acetate, etc., may be used. In some embodiments, a combination of glass and a polymer sheet may be used. It is contemplated that non-autoclave processes may also be employed. In some embodiments, the TPU polymer layer 14 can be an optical interlayer formed by extrusion. While shown as textured in FIG. 1 , the TPU layer 14 can be substantially transparent and suitable for use in window unit laminates. If desired, polycarbonate can be optionally added to the TPU layer 14 to provide ballistic and impact resistance. The TPU layer 14 can have a thickness ranging from about 0.381 mm to about 1.905 mm (about 0.015 inches to about 0.075 inches), for example. In some embodiments, the polymer layer 14 can be formed using calendaring, solution casting, injection molding, and other suitable methods.

[0021] The solar control film 12 may be configured to act as a carrier itself, thereby eliminating the need for an additional carrier, such as a polyethylene terephthalate (PET) carrier, which is subsequently peeled off and discarded before use. In the exemplary embodiment shown in FIG. 3 , a TPU interlayer 301 is formed on a first side of the solar control layer 300, and a TPU interlayer 302 is formed on a second side of the solar control layer 300. The TPU layers 301 and 302 may be formed in a two-pass process, as described below. The interlayer subcomponents may be collected and provided in a roll. In some embodiments, rigid outer layers 100 and 101 may be laminated with the interlayer subcomponents to provide the window unit laminate 305. Other layers may be added to impart desired functional properties, such as photovoltaic properties, electrochromic properties, impact resistance, acoustic attenuation, structural strength, and electromagnetic shielding. Layers 100 and 101 may be any of the glass materials listed herein, rigid optically clear polymer sheets, or combinations thereof.

[0022] 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, and thus the subcomponent may form part of a head-up display (HUD) window unit. In some embodiments, the interlayer 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 interlayer subcomponent. The interlayer subcomponent may include photovoltaic assemblies, electrochromic assemblies, acoustic attenuation layers, impact-resistant layers, etc. In certain embodiments, one or more such functional layers are provided as an interlayer subcomponent, with a polymer layer that becomes adhesive when heated provided on each of two opposing sides of the interlayer subcomponent.

[0023] The interlayer subcomponent may include an electromagnetic interference (EMI) shield for protecting wireless networks or other systems in a vehicle or building from electromagnetic interference. The EMI shielding layer may include multiple layers that are substantially transparent to visible light and may be provided on a polymer substrate such as PET or PEN. For example, alternating layers of dielectrics or metal oxides and metals may be formed as a stack and combined with other layers in the interlayer subcomponent or provided as a laminate. Examples of dielectrics or metal oxides include In2O3, TiO2, Nb2O5, Ta2O5, SnO2, ZnO, or indium tin oxide (ITO). Examples of metals may be silver, gold, copper, or aluminum. In some embodiments, the subcomponent may include a stack of ITO and silver layers applied by sputter deposition or vapor deposition.

[0024] A hard coat can be combined with the interlayer subcomponents disclosed herein. For example, the hard coat can be formed from an epoxy, a resin, or the like. For example, the hard coat can be a cured layer of a resin, such as curable silica particles. For example, a UV-curable material can be used. An exemplary embodiment of a process for forming an interlayer subcomponent may include providing a solar control film or other functional carrier layer and extruding a layer of TPU onto the carrier. The solar control film may be selected from an electrochromic assembly, an infrared absorbing layer, an infrared reflective layer, a low-emissivity ("low-emissivity") layer, or other layer. In some embodiments, another TPU layer may be formed on the carrier opposite the first layer of TPU. In certain embodiments, a PVB or EVA adhesive layer may be formed on the carrier opposite the first layer of TPU. One or more layers of TPU, PVB, and / or EVA become adhesive upon heating, allowing the interlayer subcomponent to be laminated with other layers. The solar control interlayer subcomponent may be provided in a roll and laminated into a larger assembly for a window unit, with the adhesive provided as a carrier on the solar control layer and no other carrier required.

[0025] In certain embodiments, the solar control layer 300 can be a multilayer stack with electrochromic properties. An electrochromic assembly can include an electrochromic material with transparent electrodes formed on each of its opposing surfaces. The electrochromic material responds to an applied voltage. For example, transition metal oxides are used as the electrochromic material. In some embodiments, a transparent conductive layer can be disposed on top of a layer of tungsten oxide ("WO") electrochromic material disposed on a PET substrate. Such electrochromic materials can be deposited by methods such as sputtering or chemical vapor deposition. Electrochromic solar control layers or films function by adjusting the total light transmittance in the visible and infrared regions. In this example, it is a variable transmittance solar control film.

[0026] In other embodiments, the solar control layer 300 can be an infrared absorbing or infrared reflective layer, which is a fixed transmittance solar control layer. Other variable transmittance and fixed transmittance technologies are contemplated. For example, metal oxide nanoparticles, infrared absorbing nanoparticles such as antimony tin oxide ("ATO") and ITO, metal boride nanoparticles, and metalized substrate films such as aluminum or silver deposited by vacuum evaporation or sputtering can be used in the solar control layer. 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 substantially transparent and suitable for window unit laminates. Infrared-reflective films incorporating metals and / or metal oxides to block radiation in the visible range may be utilized in these subcomponents. In some embodiments, a transparent metal layer or a series of metal and dielectric layers may be applied by sputter deposition, vacuum evaporation, or other processes. For example, a layer of silver or a silver-gold alloy may be applied. In some embodiments, the dielectric material may be zirconium oxide, tantalum oxide, tungsten oxide, indium tin oxide, or the like. In some embodiments, the interlayer subcomponent or the window unit laminate may include an infrared-reflective film. In some embodiments, a low-emissivity layer may be used, and such a layer may include a sputter-deposited silver layer between layers of a dielectric material such as titanium dioxide. In some embodiments, silica or silica-based materials may be applied by a sol-gel process. In some embodiments, an interlayer subcomponent or a laminate for a window unit may include a low-emissivity layer.

[0027] In certain embodiments, the polymer or TPU interlayers 301, 302 may be formed by extrusion using a flat die. The interlayers 301, 302 may be encapsulating tie layers that adhere to the substrate 300 and the rigid outer layers 100, 101. In some embodiments, the layers 100, 101 may be rigid sheets, such as glass panes, and may be any of the glass materials described herein. In some embodiments, the interlayer or interlayers 301, 302 may also have excellent optical clarity, durability, favorable thermal properties to compensate for differences in the thermal expansion coefficients of different layers, and mechanical properties required for windows in automobiles, other vehicles, and / or buildings. In certain embodiments, the interlayers 301, 302 provide impact resistance to the composite structure. In another embodiment, the interlayers 301 and 302 may include polycarbonate (PC) to provide ballistic resistance. In some embodiments, one or more interlayers can provide structural strength and load-bearing capacity to the composite structure in case the outermost glass pane breaks. 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 can be used. TPU exhibits good adhesion and also provides impact and ballistic resistance.

[0028] In some embodiments, intermediate layers 301, 302 may have the same thickness, forming a symmetrical composite structure. In other embodiments, intermediate layers 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, 1 mil is 1 / 1000 of an inch (0.0254 mm). In some embodiments, interlayers 301, 302 can be two different polymeric materials of equal or different thicknesses. For example, at least one of interlayers 301 and 302 can be a PVB interlayer, an acoustical-grade interlayer that may include PVB or polyvinyl acetal (PVA), a solar control interlayer, a structural interlayer that may include PVB or an ionomer, an EVA interlayer, an optical-grade interlayer, a solar energy collection assembly such as a photovoltaic assembly, and / or an electrochromic assembly. In certain embodiments, the acoustical interlayer can have a stack of PVB, PET, acrylate, PET, and PVB. In some embodiments, an acrylate acoustical layer is used.

[0029] As noted above, the interlayers 301, 302 can be two different polymeric materials with equal or unequal thicknesses. Examples include, but are not limited to: (a) a standard PVB interlayer containing 38 phr of triethylene glycol bis(2-ethylhexanoate) plasticizer; (b) an acoustic grade PVB interlayer, such as Eastman Saflex Q-series®, Eastman Saflex E-series®, Seksisui S-Lec®, and Kuraray acoustic grade Tosifol®; (c) a solar control PVB, TPU, or ionomer interlayer to reduce heat gain; (d) a structural PVB interlayer containing 20 phr of triethylene glycol bis(2-ethylhexanoate); and (e) a structural ionomer, such as Kuraray's SentryGlas®. Plus; (f) an optical-grade EVA interlayer; (g) an energy-harvesting interlayer containing inorganic quantum dots or other solar concentrators; and / or (h) an ion-conducting interlayer, such as U.S. Patent Application No. 17 / 550,090, entitled "Optically Transparent Polymer Electrolyte Films," filed December 14, 2021 (the "'090 Application"), the entire disclosure of which is incorporated herein by reference. In certain embodiments, the electrolyte disclosed in the '090 Application may be used in electrochromic assemblies having transparent electrodes. In certain embodiments, the electrolyte may be a transparent ion-conducting interlayer film. The ion-conducting interlayer film may 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 acrylic monomer. In some embodiments, other types of assemblies may be incorporated, such as photovoltaic assemblies for generating electricity from sunlight.

[0030] In some embodiments, the rigid outer layer or substrate 100, 101 may be a substantially transparent, abrasion-resistant, and / or chemically inert substrate, such as soda-lime glass, chemically or heat-strengthened glass, or coated glass with solar control capabilities, such as PPG Industries, Inc.'s SUNGATET™ windshield and AFG Industries, Inc.'s SOLARSHIELD™ glass. In some embodiments, one or more panes of glass, thick glass, silicate glass, or flat glass may be used. In some embodiments, optically clear rigid polymer sheets, such as polycarbonate sheets, may be used as layer 100, layer 101, or both. In some embodiments, rigid sheets of acrylic, polyacrylate, or polymethyl methacrylate may be used.

[0031] In the exemplary embodiment shown in FIG. 4 , subcomponent 356 may include solar control layer 350, a layer of TPU 352 formed on a first surface of solar control layer 350, and a layer 354 on a second surface opposite TPU layer 352, selected from polyvinyl butyral (PVB), polymethyl methacrylate (PMMA), polycarbonate (PC), or another polymer. Layer 354 on the second surface opposite TPU layer 352 may provide acoustic damping or other functionality. In some embodiments, a second layer of TPU or other adhesive polymer may be formed on layer 354. Subcomponent 356, having one or more layers of TPU or other adhesive polymer, may be provided on a roll. In some embodiments, solar control layer 350 may function as a carrier layer, for example, by providing or supplying an electrochromic assembly, an infrared-absorbing layer, an infrared-reflective layer, or a low-emissivity layer.

[0032] Disclosed herein are exemplary methods for manufacturing an interlayer subcomponent having a carrier layer as described above. It is also possible to lay up the individual layers 300, 301, and 302 separately prior to lamination. However, this adds complexity to the lamination process, making it costly and time-consuming. In certain embodiments, the interlayers 301 and 302 may be extruded, either in separate passes or simultaneously, onto the solar control layer 300, which may function as a carrier layer in this context. In some embodiments, the layers 300, 301, and 302 may be combined into a single multilayer subcomponent, which is sold in rolls and may be cut to size immediately prior to lamination.

[0033] In certain embodiments, an existing solar control layer 300 may be obtained and used as a carrier for casting at least one adhesive layer. For example, adhesive layers 301 and 302 may be cast onto the existing solar control layer 300. Suitable solar control layers readily available on the market from a variety of sources may be used. Examples include XIR-70, XIR-75, V-Kool, and Huper Optik™ films from Eastman Chemical Company, ULTRA PERFORMANCE™ 75 film from Bekaert Specialty Films, LLC, S-LEC™ sound and heat insulation film from Sekisui Chemical Co., Ltd., and 3M's Prestige series window films.

[0034] 5 shows a schematic diagram of an exemplary system for applying an adhesive layer to one side of a solar control layer, according to some embodiments. System 400 is configured to perform the first pass of a two-pass process, and may apply a first adhesive layer and a second adhesive layer to the solar control layer in separate passes through system 400. In some embodiments, system 400 may be used to apply a single layer of adhesive to the solar control layer. These systems may be used to form interlayer subcomponents having at least one adhesive layer on a solar control layer or other functional layer for incorporation into window unit laminates.

[0035] As shown in FIG. 5 , the flat die 402 can be fed from a single- or twin-screw extruder to extrude the adhesive layer 414. The solar control layer 412 can be provided on a roll 408. As the solar control layer 412 is unwound, the adhesive layer 414 can be cast or extruded onto one side of the solar control layer 412 and passed between a pair of nip rolls 404 and 406. The solar control layer 412 acts as a carrier layer; in this case, no additional PET or PEN layer is required. The resulting interlayer subcomponent 415 can be collected on a winder 410. In certain embodiments, a melt pump can be positioned adjacent to the die 402, or hot air can be blown toward the adhesive to maintain the desired tackiness of the material. The adhesive can be a thermoplastic polyurethane (TPU) that becomes adhesive when heated. Other polymer coatings, such as polyvinyl butyral (PVB) and ethylene vinyl acetate (EVA), can also be used.

[0036] 6 shows a schematic of an exemplary system 500 for applying an adhesive layer to the side of the solar control layer 412 opposite the adhesive 414. System 500 can be configured similarly to system 400, and the coated solar control layer 412 can be coated on the opposite side of the solar control layer 412 in a second pass through the system. In some embodiments, another system 500 can be positioned adjacent to system 400 to apply a second adhesive layer coating.

[0037] As shown in FIG. 6 , the flat die 502 can be fed from a single- or twin-screw extruder to extrude the adhesive layer 514. The subcomponent 415 can be provided on a roll 508. As the subcomponent 415 is unwound, the adhesive layer 514 is cast onto the side of the solar control layer 412 opposite the adhesive 414 and passes between a pair of nip rolls 504 and 506. The solar control layer 412 acts as a carrier layer; in this case, no additional PET or PEN layer is required. The interlayer subcomponent 515 is collected on a winder 510 and can 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 positioned adjacent to the die 502, or hot air can be blown toward the adhesive to maintain the desired tackiness of the material. The adhesive 514 can be a thermoplastic polyurethane (TPU) that becomes adhesive when heated. Other polymer coatings such as polyvinyl butyral (PVB) and ethylene vinyl acetate (EVA) may be used.

[0038] 6 shows a schematic of an exemplary system 500 for applying an adhesive layer to the side of the solar control layer 412 opposite the adhesive 414. System 500 can be configured similarly to system 400, and the coated solar control layer 412 can be coated on the opposite side of the solar control layer 412 in a second pass through the system. In some embodiments, another system 500 can be positioned adjacent to system 400 to apply a second adhesive layer coating. As shown in FIG. 6 , the flat die 502 can be fed from a single- or twin-screw extruder to extrude the adhesive layer 514. The subcomponent 415 can be provided on a roll 508. As the subcomponent 415 is unwound, the adhesive layer 514 is cast onto the side of the solar control layer 412 opposite the adhesive 414 and passes between a pair of nip rolls 504 and 506. The solar control layer 412 acts as a carrier layer; in this case, no additional PET or PEN layer is required. The middle layer subcomponent 515 is collected on a winder 510 and can 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 positioned adjacent to the die 502, or hot air can be blown toward the adhesive to maintain the desired tackiness of the material. The adhesive 514 can be a thermoplastic polyurethane (TPU) that has adhesive properties when heated. Other polymer coatings such as polyvinyl butyral (PVB) and ethylene vinyl acetate (EVA) may be used.

[0039] In further embodiments, system 500 may be used to coat PVB, PMMA, PC, or other polymers on the solar control layer 412 opposite adhesive layer 414. In certain embodiments, a layer of TPU or other adhesive may be coated onto the assembly opposite layer 414. In some embodiments, two interlayers may be cast simultaneously using a single sheet die or a two sheet die.

[0040] As shown in FIG. 7, it is envisioned to provide a window unit 602 having a solar control interlayer subcomponent 610. The interlayer subcomponent 610 may be installed within a window frame 612. Other contemplated embodiments may also include other structures and assemblies, such as an acoustical grade interlayer (which may include PVB or polyvinyl acetal (PVA)), a structural interlayer (which may include PVB or an ionomer), a solar energy collection assembly such as a photovoltaic assembly, and / or an electrochromic assembly. In certain embodiments, the window unit may be used on a particular side of a building and may include transparent and translucent or opaque portions. For example, the transparent portion may include energy collection elements such as quantum dots disposed within the transparent portion, and photovoltaic cells may be disposed in portions where transparency is not required, such as opaque portions that do not form part of the window area. In other embodiments, photovoltaic cells may be disposed on one or more edges of the laminate or window unit. [Example]

[0041] Samples of the exemplary interlayers and laminates described herein were prepared and evaluated. Example 1 A three-layer film was formed by disposing a first thermoplastic polyurethane layer on one side of a solar-control carrier layer and a second thermoplastic polyurethane layer on a second side of the carrier layer (where the second side is opposite the first side). The first and second thermoplastic polyurethane layers were extruded from an aliphatic polyether resin sold by BASF as Elastollan® L1275A10 and had a nominal thickness of 0.025 inches or 0.635 mm. The solar-control carrier layer was architectural window film C-1 sold by Madico as SolarGrey35. The film transmitted 32.3% visible light and had a haze of 1.03%. The three-layer film was sealed between two rigid borosilicate glass plates, each 0.125 inches or 3.175 mm thick, and laminated using a vacuum autoclave at 239°F (115°C) and 100 psi. The obtained laminates S-1A and S-1B had an average light transmittance and haze of 37.7% and 1.31%, respectively.

[0042] Example 2 A three-layer film was formed by disposing a first thermoplastic polyurethane layer on one side of a solar-control carrier layer and a second thermoplastic polyurethane layer on a second side of the carrier layer (where the second side is opposite the first side). The first and second thermoplastic polyurethane layers were extruded from an aliphatic polyether resin sold by BASF as Elastollan® L1275A10 and had a nominal thickness of 0.025 inches or 0.635 mm. The solar-control carrier layer was architectural window film, C-2, sold by Madico as SolarBronze 35. The film transmitted 34.1% visible light and had a haze of 1.09%. The three-layer film was sealed between two rigid borosilicate glass plates, each 0.125 inches or 3.175 mm thick, and laminated using a vacuum autoclave at 239°F and 100 psi. The obtained laminates S-2A and S-2B had an average light transmittance and haze of 39.9% and 1.075%, respectively.

[0043] Example 3 A three-layer film was formed by disposing a first thermoplastic polyurethane layer on one side of a solar-control carrier layer and a second thermoplastic polyurethane layer on a second side of the carrier (where the second side is opposite the first side). The first and second thermoplastic polyurethane layers were extruded from an aliphatic polyether resin sold by BASF as Elastollan® L1275A10 and had a nominal thickness of 0.025 inches or 0.635 mm. The solar-control carrier layer was an architectural window film, C-3, sold by Madico as Optivision® Reflective5. The film transmitted 6.53% visible light and had a haze of 3.72%. The three-layer film was sealed between two rigid borosilicate glass plates, each 0.125 inches or 3.175 mm thick, and laminated using a vacuum autoclave at 239°F and 100 psi. The obtained laminates S-3A and S-3B had an average light transmittance and haze of 6.635% and 4.485%, respectively.

[0044] Comparative Example 1 Two laminates were prepared by laying up two layers of thermoplastic polyurethane extruded from an aliphatic polyether resin sold by BASF as Elastollan® L1275A10. Each layer had a nominal thickness of 0.025 inches or 0.635 mm. The two layers were sealed between two hard 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 placed between the two thermoplastic polyurethane layers. The resulting laminates, CS-1A and CS-2A, had average light transmittance and haze of 93.5% and 0.83%, respectively.

[0045] As can be seen from Examples 1 to 3 and Comparative Example 1, and as summarized in Table 1, placing a thermoplastic polyurethane layer on the first and second sides of a functional carrier layer and then laminating the three layers between two hard glass plates did not significantly adversely affect the light transmittance and haze value of the resulting composite. [Table 1] As shown in Table 1 above, in all three examples, increases in light transmittance and haze were observed compared to the respective functional carrier films, but the optical properties were still within acceptable limits.

[0046] 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 as exemplary only, with a true scope and spirit of the embodiments being indicated by the following claims.

[0047] For example, according to one aspect, in a first embodiment, an interlayer subcomponent is provided, which may comprise a carrier layer and at least one thermoplastic polyurethane layer on a surface thereof, where the at least one thermoplastic polyurethane layer is adhesive when heated, and the carrier layer is a solar control layer. The second embodiment is the first embodiment, wherein the carrier layer is an electrochromic assembly, an infrared absorbing layer, an infrared reflective layer, or a low emissivity layer. A third embodiment is any combination of the first and second embodiments, wherein the thermoplastic polyurethane layer is an optical interlayer formed by extrusion. A fourth embodiment is any combination of the first to third embodiments, wherein a first thermoplastic polyurethane layer is disposed on a first side of the carrier layer and a second thermoplastic polyurethane layer is disposed on a second side of the carrier layer, the second side being opposite the first side, and the first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer are adhesive when heated. A fifth embodiment is any combination of the first to fourth embodiments, in which the first and second thermoplastic polyurethane layers have the same thickness. A sixth embodiment is any combination of the first to fifth embodiments, in which the first and second thermoplastic polyurethane layers have different thicknesses. A seventh embodiment is any combination of the first through sixth embodiments, wherein the first thermoplastic polyurethane layer, the second thermoplastic polyurethane layer, or both thermoplastic polyurethane layers are wedge-shaped.

[0048] An eighth embodiment is any combination of the first to seventh embodiments, where the subcomponent forms part of a head-up display (HUD) window unit. A ninth embodiment is any combination of the first through eighth embodiments, wherein a first thermoplastic polyurethane layer is disposed on a first surface of the carrier layer, and further comprising a second layer on a second surface opposite the first surface, 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). A tenth embodiment is any combination of the first through ninth embodiments, wherein a second thermoplastic polyurethane layer is disposed on the second layer.

[0049] An eleventh embodiment is any combination of the first through tenth embodiments, wherein a first thermoplastic polyurethane layer is disposed on a first surface of the carrier layer, and further comprising a layer providing acoustic attenuation on a second surface of the carrier layer. A twelfth embodiment is any combination of the first through eleventh embodiments, wherein a first thermoplastic polyurethane layer is disposed on a first side of the carrier layer, and further comprising a layer providing impact resistance on a second side of the carrier layer. A thirteenth embodiment is any combination of the first through twelfth embodiments, wherein a first thermoplastic polyurethane layer is disposed on the second side of the carrier layer, and further comprising a photovoltaic assembly on the first side of the carrier layer. The fourteenth embodiment is any combination of the first to thirteenth embodiments, in which the first surface is a surface facing outward from the window unit.

[0050] A fifteenth embodiment is any combination of the first through fourteenth embodiments, wherein the photovoltaic assembly comprises a polymer layer having photovoltaic cells. A sixteenth embodiment is any combination of the first through fifteenth embodiments, wherein the photovoltaic assembly comprises a polymer layer having quantum dots. A seventeenth embodiment is any combination of the first to sixteenth embodiments, further comprising photovoltaic cells arranged along the edge of the carrier layer. An eighteenth embodiment is any combination of the first to seventeenth embodiments, further comprising photovoltaic cells arranged on the surface of a carrier layer that does not require transparency. A nineteenth embodiment is any combination of the first through eighteenth embodiments, wherein a first thermoplastic polyurethane layer is disposed on a first surface of the carrier layer, and further comprising an electrochromic assembly on a second surface of the carrier layer.

[0051] A twentieth embodiment is any combination of the first through nineteenth embodiments, wherein the electrochromic assembly comprises a transparent ion-conducting polymer electrolyte film. A twenty-first embodiment is any combination of the first to twentieth embodiments, wherein the electrochromic assembly includes a transparent electrode. A 22nd embodiment is any combination of the 1st to 21st embodiments, wherein a first thermoplastic polyurethane layer is disposed on the first side of the carrier layer, and further comprising a layer of polyvinyl butyral on the second side of the carrier layer. A 23rd embodiment is any combination of the 1st to 22nd embodiments, wherein a first thermoplastic polyurethane layer is disposed on the first side of the carrier layer, and further comprising a layer of poly(ethylene co-vinyl acetate) on the second side of the carrier layer.

[0052] In a second aspect, there is provided a first embodiment of a window unit for a vehicle or building, the window unit having an interlayer subcomponent according to any combination of the first to twenty-third embodiments above disposed between a first rigid sheet and a second rigid sheet. The 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. A third embodiment is any combination of the first and second embodiments of the window unit, wherein at least one of the first rigid sheet and the second rigid sheet comprises a polymer.

[0053] The fourth embodiment is any combination of the first to third embodiments of the window unit, further comprising an electromagnetic shield. The fifth embodiment is any combination of the first to fourth embodiments of the window unit, further comprising a low-emissivity layer. The sixth embodiment is any combination of the first to fifth embodiments of the window unit, further comprising an electrochromic assembly. The seventh embodiment is any combination of the first to sixth embodiments of the window unit further comprising a photovoltaic assembly.

[0054] In a third aspect, a first embodiment of a method of forming an interlayer subcomponent is provided, the method comprising the steps of providing a carrier layer, the carrier layer being a solar control layer, and extruding a thermoplastic polyurethane layer onto a surface of the carrier layer, the thermoplastic polyurethane layer being adhesive when heated. A second embodiment is the first embodiment of the above method, wherein the solar control layer is an electrochromic assembly, an infrared reflective layer, an infrared absorbing layer, or a low emissivity layer. A third embodiment is any combination of the first and second embodiments of the above method, further comprising the step of extruding a first thermoplastic polyurethane layer onto a first side of the carrier layer and a second thermoplastic polyurethane layer onto a second side of the carrier layer, the first side being opposite the second side.

[0055] A fourth embodiment is any combination of the first to third embodiments of the above method, wherein a first thermoplastic polyurethane layer is extruded onto a first side of the carrier layer in a first pass, and a second thermoplastic polyurethane layer is extruded onto a second side of the carrier layer in a second pass. A fifth embodiment is any combination of the first to fourth embodiments of the above method, in which the first and second passes are carried out in the same extruder. A sixth embodiment is any combination of the first to fifth embodiments of the method, wherein the first thermoplastic polyurethane layer and said second thermoplastic polyurethane layer are co-extruded. A seventh embodiment is any combination of the first through sixth embodiments of the method described above, further comprising collecting the intermediate layer subcomponent into a roll.

[0056] An eighth embodiment is any combination of the first through seventh embodiments of the above method, further comprising the step of extruding a first thermoplastic polyurethane layer onto a first side of the carrier layer and a second layer onto a second side of the carrier layer, the first side being opposite the second side, and the second layer being selected from the group consisting of polyvinyl butyral, polymethyl methacrylate, and polycarbonate. A ninth embodiment is any combination of the first to tenth embodiments of the method, further comprising laminating a first hard sheet and a second hard sheet to the intermediate layer subcomponent, wherein the intermediate layer subcomponent is disposed between the first hard sheet and the second hard sheet. A tenth embodiment is any combination of the first to eleventh embodiments of the method, wherein at least one of the first rigid sheet and the second rigid sheet comprises glass. An eleventh embodiment is any combination of the first to tenth embodiments of the method, wherein at least one of the first and second rigid sheets is a polymeric rigid sheet.

Claims

1. a carrier layer and at least one thermoplastic polyurethane layer thereon; the at least one thermoplastic polyurethane layer is adhesive when heated, and the carrier layer is a solar control layer; Mid-tier subcomponents.

2. The interlayer subcomponent of claim 1 , wherein the carrier layer is an electrochromic assembly, an infrared absorbing layer, an infrared reflective layer, or a low emissivity layer.

3. The interlayer subcomponent of claim 1 , wherein the thermoplastic polyurethane layer is an extruded optical interlayer.

4. 2. The interlayer subcomponent of claim 1, wherein a first thermoplastic polyurethane layer is disposed on a first side of the carrier layer and a second thermoplastic polyurethane layer is disposed on a second side of the carrier layer, the second side being opposite the first side, and the first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer are adhesive when heated.

5. The interlayer subcomponent of claim 4 , wherein the first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer have the same thickness.

6. The interlayer subcomponent of claim 4 , wherein the first thermoplastic polyurethane layer and the second thermoplastic polyurethane layer have different thicknesses.

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

9. 10. The interlayer subcomponent of claim 1, wherein a first thermoplastic polyurethane layer is disposed on a first surface of the carrier layer and further comprising a second layer on a second surface opposite the first surface, 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 interlayer subcomponent of claim 9 , wherein a second thermoplastic polyurethane layer is disposed on the second layer.

11. The interlayer subcomponent of claim 1 , further comprising a layer providing acoustic attenuation on a second side of the carrier layer, the first thermoplastic polyurethane layer being disposed on a first side of the carrier layer.

12. 10. The midlayer subcomponent of claim 1, further comprising a first thermoplastic polyurethane layer disposed on a first side of the carrier layer, and a layer providing impact resistance on a second side of the carrier layer.

13. The interlayer subcomponent of claim 1 , further comprising a first thermoplastic polyurethane layer disposed on the second side of the carrier layer and a photovoltaic assembly on the first side of the carrier layer.

14. The interlayer subcomponent of claim 13 , wherein the first surface is an exterior-facing surface of a window unit.

15. The interlayer subcomponent of claim 13 , wherein the photovoltaic assembly comprises a polymer layer having photovoltaic cells.

16. The interlayer subcomponent of claim 13 , wherein the photovoltaic assembly comprises a polymer layer having quantum dots.

17. The midlayer subcomponent of claim 16 further comprising photovoltaic cells arranged along an edge of the carrier layer.

18. 17. The interlayer subcomponent of claim 16, further comprising photovoltaic cells arranged on a surface of the carrier layer that is not required to be transparent.

19. The interlayer subcomponent of claim 1 , further comprising a first thermoplastic polyurethane layer disposed on a first surface of the carrier layer and an electrochromic assembly on a second surface of the carrier layer.

20. 20. The interlayer subcomponent of claim 19, wherein the electrochromic assembly comprises a transparent, ion-conducting polymer electrolyte film.

21. 20. The interlayer subcomponent of claim 19, wherein the electrochromic assembly includes a transparent electrode.

22. The interlayer subcomponent of claim 1 , further comprising a first thermoplastic polyurethane layer disposed on a first surface of the carrier layer and a layer of polyvinyl butyral on a second surface of the carrier layer.

23. 10. The interlayer subcomponent of claim 1, further comprising a first thermoplastic polyurethane layer disposed on a first surface of the carrier layer and a layer of poly(ethylene co-vinyl acetate) on a second surface of the carrier layer.

24. 10. A window unit for a vehicle or building, comprising an interlayer subcomponent according to claim 1 disposed between a first rigid sheet and a second rigid sheet.

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

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

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

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

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

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

31. providing a carrier layer, the carrier layer being a solar control layer; extruding a thermoplastic polyurethane layer onto a surface of the carrier layer, the thermoplastic polyurethane layer being adhesive when heated; 10. A method for forming an intermediate layer subcomponent, comprising:

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

33. 32. The method of claim 31 , further comprising the step of extruding a first thermoplastic polyurethane layer onto a first side of the carrier layer and extruding a second thermoplastic polyurethane layer onto a second side of the carrier layer, the first side being opposite the second side.

34. 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. 35. The method of claim 34, wherein the first pass and the second pass are carried out in the same extruder.

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

37. 32. The method of claim 31 further comprising collecting the middle layer subcomponent into a roll.

38. 32. The method of claim 31, further comprising the step of extruding a first thermoplastic polyurethane layer onto a first side of the carrier layer and a second layer onto a second side of the carrier layer, the first side being opposite the second side, and the second layer being selected from the group consisting of polyvinyl butyral, polymethyl methacrylate, and polycarbonate.

39. 32. The method of claim 31, further comprising laminating a first rigid sheet and a second rigid sheet to the intermediate layer subcomponent, wherein the intermediate layer subcomponent is disposed between the first rigid sheet and the second rigid sheet.

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

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

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