Protective structure for laminates

Abstract

A protective structure for use with a laminate, and a laminate containing the protective structure, are provided, which can be used in a variety of different applications such as shatterproof windows for vehicles and buildings. The protective structure includes a first layer comprising polycarbonate (PC), polyethylene terephthalate (PET), thermoplastic polyurethane (TPU), acrylic, or a combination thereof. The first layer has a first surface and a second surface opposite to the first surface. The structure further includes a hard coating on the first surface of the first layer and a second layer comprising thermoplastic polyurethane (TPU) in contact with the second surface of the first layer. By forming the protective structure on a single film or layer, material handling and costs are reduced. Furthermore, the structure has few independent webs, which allows it to be manufactured with reduced thickness, further reducing manufacturing costs.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims the benefit of U.S. Provisional Patent Application No. 63 / 519,422, filed on August 14, 2023, the entire disclosure of which is incorporated herein by reference for all purposes. This description generally relates to protective structures such as films, layers, coatings or covers for use in laminated assemblies, and more particularly to outdoor safety films for use in splash - resistant windows.

Background Art

[0002] Fragment is a term that refers to shards or splinters that break off from hard glass pieces when the glass cracks. When strong winds, or objects originating from the outside of a vehicle or building collide with a window, fragments can fly inside and cause serious lacerations. Injuries caused by broken glass can endanger life, result in permanent scars, or cause amputations. Safety or "splash - resistant" window films provide an additional barrier that can increase resistance to glass splashing and / or penetration, improving the bullet - proof and security performance of windows. These protective films typically include a polyethylene terephthalate (PET) layer with a scratch - resistant outer hard coat. The PET layer is adhered to the outer surface of the glass using an adhesive intermediate layer to protect individuals and possessions from glass splashing.

Summary of the Invention

[0003] A protective structure for use with a laminate, and a laminate, are provided that can be used in a variety of different applications such as vehicle and building windows. The laminate can be particularly useful in applications that require splash - resistance or impact - resistance, such as, for example, splash - resistant glass and / or bullet - proof glass, sunroofs, windshields, light bulbs, skylights, security doors, screen protectors, curtain walls, mass transit vehicles, ocean vessels, military facilities, critical infrastructure, etc. In one embodiment, the protective structure includes a first layer comprising a material selected from the group consisting of polycarbonate (PC), polyethylene terephthalate (PET), thermoplastic polyurethane (TPU), acrylic, and combinations thereof, having a first surface and a second surface opposite to the first surface. The structure further includes a hard coating on the first surface of the first layer and a second layer comprising thermoplastic polyurethane (TPU) in contact with the second surface of the first layer. In the embodiment, the TPU layer is extruded directly onto the surface of the first layer to form a single structure, film, or layer. In the exemplary embodiment, the first layer includes PET. By forming a protective structure including single layers of TPU and PET, material handling and costs are reduced. Furthermore, the structure has few independent webs and is manufactured with reduced thickness, which can further reduce manufacturing costs.

[0004] In one embodiment, the structure has a thickness of about 0.015 inches to about 0.020 inches, or about 0.016 inches to about 0.018 inches, or about 0.017 inches. The first layer may have a thickness of about 0.005 inches to about 0.009 inches, or about 0.007 inches. The second layer may have a thickness of about 0.008 inches to about 0.012 inches, or about 0.010 inches. The TPU layer may contain any suitable thermoplastic polyurethane, such as polyester, polyether, or polycaprolactone, which is substantially optically transparent and has sufficient protective properties for bonding to various materials such as glass, polycarbonate, and acrylic. In exemplary embodiments, the TPU layer includes an aliphatic TPU, preferably a polyetheraliphatic TPU. The polyetheraliphatic TPU may have a hardness in the range of about 60 Shore A to about 100 Shore A or about 70 Shore A to about 85 Shore A. In embodiments, a hard coating is a scratch-resistant "hard" coating comprising one or more materials that prevent scratches from forming on the first layer. Suitable materials for the hard coating include, but are not limited to, silicone, solvent-based acrylic, solvent-free acrylic, diamond-like carbon (DLC), and combinations thereof. Furthermore, or alternatively, the hard coating may include additives, filters, and / or bonding agents that impart scratch resistance.

[0005] The hard coating may be applied to the first layer by any suitable method, such as drop casting, dip coating, optical deposition, vacuum deposition, electrospinning, electrospray, layer-by-layer deposition, or spin coating. In an exemplary embodiment, the hard coating is sputter-coated onto the surface of the PET layer. In the embodiment, the protective structure is substantially optically transparent. Therefore, the structure may have a haze of less than about 4% or less than about 3%, preferably less than or equal to about 1%. The structure may have a light transmittance of more than about 50%, or more than about 70%, preferably more than or equal to about 90%. The structure may have a yellowness index (YI) of less than about 2 or less than 1. In embodiments, the protective structure further includes a third layer in contact with the surface of the second layer opposite the first layer. The third layer includes a release liner, such as interleaving paper, which can be removed from the TPU layer before the structure is applied to a substrate such as glass. The interleaving paper may have a thickness of about 0.002 inches to about 0.0006 inches or about 0.004 inches.

[0006] In certain embodiments, the structure may be bonded to a single transparent substrate or layer, such as glass or polycarbonate. In other embodiments, the structure may be part of a laminated assembly that includes one or more additional layers bonded to the transparent substrate. The transparent substrate may include any optically transparent material having sufficient rigidity for a given application. Suitable materials for the substrate include, but are not limited to, glass, artificial glass, polycarbonate, acrylic resin, polyester, polyether, and polyurethane. In exemplary embodiments, the transparent substrate includes glass or polycarbonate. In another embodiment, a laminate is provided that includes one of the above-described protective structures. In another embodiment, a window is provided that includes one of the above-described protective structures.

[0007] In another embodiment, the laminate comprises an optically transparent substrate and The aforementioned The structure includes a protective structure bonded to a substrate. The protective structure includes a first layer comprising a material selected from the group consisting of polycarbonate (PC), polyethylene terephthalate (PET), thermoplastic polyurethane (TPU), acrylic, and combinations thereof. This first layer has a first surface and a second surface opposite to the first surface. The structure further includes a hard coating on the first surface of the first layer and a second layer comprising thermoplastic polyurethane (TPU) in contact with the second surface of the first layer. The TPU layer is bonded to an optically transparent substrate. In embodiments, the optically transparent substrate may include one of glass, artificial glass, polycarbonate, acrylic resin, polyester, polyether, and / or polyurethane. In exemplary embodiments, the transparent substrate includes glass or polycarbonate.

[0008] In the embodiment, the protective structure is bonded to a first surface of a transparent substrate, and the laminate further includes an intermediate layer in contact with a second surface of the transparent substrate opposite to the first surface. In the embodiment, the laminate includes a second optically transparent substrate in contact with the intermediate layer opposite to the first substrate. The second substrate may include glass, artificial glass, polycarbonate, acrylic resin, polyester, polyether, and / or polyurethane. In certain embodiments, one of the protective structures and / or other layers of the laminate may include one or more functional elements having solar control properties. Preferred functional elements include, but are not limited to, light phosphoruses, ionomers, and optical elements (such as UV absorbers, UV reflectors, IR absorbers, and IR reflectors). In one embodiment, the functional elements include solar control elements such as heat absorbers, thermal reflectors, optical filters, photovoltaic assemblies, electrochromic assemblies, and combinations thereof. The accompanying drawings incorporated into and constituting portions of this specification illustrate several embodiments of the present disclosure together with this description and serve to illustrate the principles of the present disclosure. [Brief explanation of the drawing]

[0009] [Figure 1] This is a schematic cross-sectional view of the protective structure. [Figure 2] Figure 1 is a schematic cross-sectional view of a multilayer laminate including the protective structure. [Modes for carrying out the invention]

[0010] This description and accompanying drawings illustrate exemplary embodiments and should not be considered limiting, and the claims, including their equivalents, define the scope of this disclosure. Various mechanical, compositional, structural, and operational modifications may be made without departing from the scope of this description and claims, including their equivalents. In some examples, well-known structures and techniques are not shown in detail or described in this disclosure so as not to obscure it. Similar figures in two or more figures represent the same or similar elements. Furthermore, elements and their related aspects described in detail with reference to one embodiment may, whenever practical, be included in other embodiments that are 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, it can still be argued that the element is included in the second embodiment. Furthermore, the illustrations in this specification are for illustrative purposes only and do not necessarily reflect the actual shape, size, or dimensions of the system or the illustrated components.

[0011] It should be noted that, as used herein and in the appended claims, the singular forms "a," "an," and "the," and any singular use of any word, include multiple referents unless expressly and clearly limited to one. The term "include" and its grammatical variations are intended to be non-restrictive as used herein, so that the listing of items in a list does not exclude other similar items that may replace or add to the listed items. Provided are protective structures for use with laminates, which can be used in a variety of different applications such as windows in vehicles and buildings, and laminates containing such protective structures. Laminates can be particularly useful in applications requiring shatterproof or impact resistance, such as shatterproof or bulletproof glass, sunroofs, windshields, light bulbs, skylights, security doors, screen protectors, curtain walls, mass transport vehicles, marine vessels, military facilities, and critical infrastructure. In some embodiments, the protective structure and / or laminate may also include solar control properties such as light luminescent particles, ionomers, UV and / or IR light filters, and thermal filters.

[0012] In a particular embodiment, as shown in Figure 1, the protective structure 10 includes a first layer 30 having a hard coating 40, and a second layer of thermoplastic polyurethane (TPU) 20 in contact with the surface of the first layer 30 opposite the coating 40. The structure 10 may also include an optional third layer 50, such as an interlayer or release liner. The interlayer 50 functions to prevent the TPU layer 20 from adhering to other materials such as devices or packaging, and is typically removed before the structure 10 is applied to a transparent substrate such as a window or door. As shown in Figure 1, the TPU layer 20 is preferably extruded directly onto the surface of the first layer 30 to form a single structure, film, or layer 10. Forming a protective structure with a single layer reduces material handling and costs. Furthermore, this structure has few independent webs, which allows it to be manufactured with reduced thickness, further lowering manufacturing costs. Suitable materials for the first layer 30 include, but are not limited to, polycarbonate (PC), polyethylene terephthalate (PET), thermoplastic polyurethane (TPU), acrylic, and combinations thereof. In one embodiment, the first layer comprises a blend of crosslinked TPU and acrylic to form a harder layer. In another embodiment, the first layer 30 comprises PET.

[0013] In one embodiment, the structure 10 has a thickness of about 0.015 inches to about 0.020 inches, or about 0.016 inches to about 0.018 inches, or about 0.017 inches. The PET layer 30 may have a thickness of about 0.005 inches to about 0.009 inches, or about 0.007 inches. The TPU layer 20 may have a thickness of about 0.008 inches to about 0.012 inches, or about 0.010 inches. By combining the PET and TPU layers into a single layer, both layers can be made thinner than conventional protective films. Manufacturers can typically handle polymer layers that are approximately 0.015 inches or thicker. That is, by combining both layers into a single structure with a thickness of approximately 0.017 inches, the overall thickness of the protective structure can be reduced. The second layer 20 comprises a TPU that is substantially optically transparent and has sufficient protective properties for bonding to various materials such as glass, polycarbonate, and acrylic. In exemplary embodiments, the TPU comprises an aliphatic TPU, preferably a polyetheraliphatic TPU. Aliphatic TPU is the main compound that has excellent optical transparency (i.e., yellow) and does not generally decompose when exposed to UV light. Furthermore, polyetheraliphatic TPU is highly adhesive and adheres to a wide variety of materials such as polycarbonate and acrylic.

[0014] Polyetheraliphatic TPU may have a hardness in the range of approximately 60 Shore A to approximately 100 Shore A or approximately 70 Shore A to approximately 85 Shore A. Polyetheraliphatic TPU may have a tear strength of at least approximately 250 lbs / in or at least approximately 320 lbs / in as measured by ASTM D412, and an ultimate tensile strength of at least approximately 6000 psi or at least approximately 7000 psi as measured by ASTM D412. In some embodiments, the protective structure 10 may have a haze of less than about 3.5% or less than about 2%, preferably less than or equal to about 1%. The structure may have a light transmittance of more than about 50% or more than about 50%, preferably more than or equal to about 90%. The structure may have a yellowness index (YI) of less than about 2 or less than 1.

[0015] The first layer 30 may contain an adhesion promoter to enhance the bond between the first layer 30 and the TPU layer 20 and to prevent delamination of the TPU from the first layer. Suitable adhesion promoters include, but are not limited to, organosilanes, organotitanates, zirconates, zircoaluminates, alkyl phosphate esters, and metal-organic compounds. The hard coating 40 is a scratch-resistant "hard" coating comprising one or more materials that prevent scratches from forming on the first layer of the protective structure. Suitable materials for the hard coating include, but are not limited to, silicone, solvent-based acrylic, solvent-free acrylic, diamond-like carbon (DLC), and combinations thereof. Furthermore, or alternatively, the hard coating may include additives, fillers, and / or binders that impart scratch resistance. Suitable binders include, but are not limited to, inorganic nonmetal-based ceramics, polysilazane, DLC, organic polymer-based resin binders, epoxy, polycarbonate, polyethylene, and combinations thereof. Suitable fillers include, but are not limited to, titanium dioxide (TiO2), zirconium dioxide (ZrO2), aluminum hydroxide oxide (AlOOH), silicon monoxide (SiO), and combinations thereof. Suitable additives include, but are not limited to, siloxanes, eruamides, MoS2, graphite, oleic acid amides, zinc oxide (ZnO), barium oxide (BaO), lead dioxide (PbO), and combinations thereof.

[0016] In exemplary embodiments, the hard coating 40 comprises a solvent-based acrylic or a solvent-free acrylic. The hard coating 40 can be applied to the first layer 30 by any suitable method such as drop casting, dip coating, optical deposition, vacuum deposition, electrospinning, electrospray, layer-by-layer deposition, or spin coating. In exemplary embodiments, the coating 40 is sputter-coated onto the surface of layer 30. In certain embodiments, the TPU is selected to be bendable or deformable such that a bendable or curved laminate having solar control properties is produced. In this embodiment, the laminate may be used with, for example, curved glass, polycarbonate, etc. to manufacture, for example, arched windows, arch windows, bay windows, turret windows, curved vehicle windows, bulletproof curved windows, and the like.

[0017] Referring now to FIG. 2, another embodiment of the laminate 100 includes an outer layer 110 and a protective structure 10 laminated to the outer layer 110. The protective structure 10 includes a first layer 30 having a hard coating 40 and a second layer of thermoplastic polyurethane (TPU) 20 contacting the surface of the first layer 30 opposite the coating 40. The TPU layer 20 is also joined to the surface of the outer layer 110. The release paper 50 (see FIG. 1) is removed before the TPU layer 20 is joined to the outer layer 110. As in the previous embodiments, the first layer 30 may include combinations thereof such as polycarbonate (PC), polyethylene terephthalate (PET), thermoplastic polyurethane (TPU), acrylic, and crosslinked blends of acrylic and TPU.

[0018] The outer layer 110 includes an optically transparent and substantially rigid material. Suitable materials for the outer layer 110 include, but are not limited to, glass, artificial glass, or any well-known glass alternatives such as polycarbonate, acrylic resin, polyester, polyether, and polyurethane. In certain embodiments, the laminate 100 may further include an additional intermediate layer and / or an optically transparent layer attached to the surface of the layer 110 opposite the protective structure 10. In such an embodiment, the protective structure 10 is joined to the first surface of the substrate 110, and the laminate further includes an intermediate layer (not shown) joined to the second surface of the substrate opposite the first surface. In an embodiment, the laminate includes a second optically transparent substrate (not shown) joined to the intermediate layer opposite the first substrate. The second substrate may include any well-known glass alternatives such as glass, artificial glass, or polycarbonate, acrylic resin, polyester, polyether, and polyurethane.

[0019] In certain embodiments, either the protective structure 10 or any one of the other layers of the laminate 100 may include one or more functional elements contained therein. Suitable functional elements include, but are not limited to, solar control elements, light-emitting groups, 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, light filters, photovoltaic assemblies, electrochromic assemblies, and combinations thereof. In certain embodiments, either the protective structure 10 or any one of the other layers of the laminate 100 may include one or more of an optical element, a material that allows visible light transmission, a material that reflects or absorbs UV and / or IR light, and / or a layer made of these materials. For example, an IR blocking optical element may be configured to reflect or absorb light having wavelengths between about 700 nm and 1 mm, preferably between about 700 nm and about 1400 nm (i.e., near-infrared wavelengths), more preferably between about 750 nm and about 1200 nm. In one embodiment, the optical element includes an IR reflective coating. Suitable materials that reflect light having wavelengths in the IR range include metal coatings or metal-based coatings such as two-layer or three-layer silver coatings, liquid crystal materials, etc., which selectively operate to transmit or scatter IR light, etc.

[0020] In another embodiment, the optical element includes an IR absorbing substance such as an IR absorbing dye, a copper salt composition such as copper phosphonate, nanoparticles (such as zinc oxide, antimony tin oxide (ATO), lanthanum hexaboride (LaB), etc.), an infrared filter such as blue glass, an intermediate layer film containing IR shielding microparticles, etc. 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 can include a UV blocking material, while the second TPU layer includes IR blocking particles.

[0021] In certain embodiments, either the protective structure 10 or any other layer of the laminate 100 may include an optical element, layer, or material capable of either reflecting or absorbing UV light. The UV-blocking optical element preferably reflects or absorbs light having wavelengths between about 10 and 410 nm, more preferably above about 380 nm, and even more preferably between about 380 and 410 nm. The optical element may include any suitable material configured to reflect or absorb UV light, such as UV-absorbing, blocking, or selective additives. Suitable UV-absorbing, blocking, or selective additives for this disclosure include bezophenone, cinnamic acid derivatives, benzoic acid esters, salicylic acid, terephthalic acid including resorcinol and phenols, isophthalic acid, pentamethylpiperidine derivatives, salicylates, benzotriazoles, cyanoacrylates, benzylidene, malonates, and oxalamides in combination with nickel chelates and sterically hindered amines.

[0022] Alternatively, the UV-blocking optical element may include a light filter layer within the TPU layer. Suitable optical elements for use in this specification include sheet-type polarizers, dichroic materials, and reflective filter materials that reduce broadband UV rays. For example, blue or green tinted glass that significantly reduces UV transmission, or a blue or green tinted polymer intermediate layer, a UV-reducing paint or lacquer coating or layer, or a polymer film may be suitable as a UV-blocking material. In a particular embodiment, the optical element includes an IR blocking layer capable of either reflecting or absorbing IR light, and a separate UV blocking element capable of either reflecting or absorbing UV light. The IR blocking element is preferably disposed in contact with the UV blocking element and one of the first and second thermoplastic polyurethane layers 130, 140. The IR blocking element can either reflect or absorb light having wavelengths between about 700 nm and about 1 mm, preferably between about 700 and about 1400 nm, and more preferably between about 750 and about 1200 nm. The UV blocking element can either reflect or absorb light having wavelengths between about 10 and 410 nm, preferably between about 380 and 410 nm.

[0023] 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 two or three layers of silver. A more complete description of optical elements that absorb or reflect IR and UV light can be found in International Application PCT / US2021 / 40300, filed July 20, 2021, entitled Laminates with Optical Layers or Materials, which has been assigned to the assignee of the present invention, and whose entire description is incorporated herein by reference for all purposes. In certain embodiments, either the protective structure or any other layer of the laminate 100 may contain one or more luminescent phosphotes. In exemplary embodiments, the luminescent phosphote is a fluorophore, which is a fluorescent chemical compound configured to re-emit light upon photoexcitation. The fluorophore typically contains several mixed aromatic groups or a planar or cyclic molecule having several π bonds.

[0024] The luminescent phore may be configured to absorb most of the NIR or UV photons passing through the laminate. In one embodiment, the protective structure includes a phosphorescent organic molecule or a blend of multiple luminescent phores (such as quantum dots or organic dyes) that work to reduce reabsorption loss and improve the overall absorption efficiency of the spectrum. In some embodiments, the protective structure, or any one of the other layers of the laminate 100, may contain an ionomer or a polymer as a pendant group portion, comprising repeating units that are both electrically neutral and ionized, covalently bonded to the polymer backbone. A certain mole percent, e.g., 15% or less, is ionized. The ionomer may have specific physical properties such as conductivity and viscosity.

[0025] In certain embodiments, either the protective structure or one of the other layers of the laminate 100 may include photovoltaic functions, electrochromic functions, and / or other functions for conductive properties. In such an embodiment, the laminate 100 includes a photovoltaic assembly inside. For example, quantum dots can be provided inside either the protective structure 10 or one of the other layers of the laminate 100. Another suitable alternative to energy-generating quantum dots is organic solar cells (OPVs), which may be used here. Organic photovoltaic technology is rapidly emerging because it improves battery efficiency and beneficial performance life, and demonstrates the possibility of roll-to-roll manufacturing using solution processing methods. OPVs can be absorbers in any color and enable the fabrication of highly efficient transparent devices, making them an attractive alternative. Using the diversity of organic materials, absorbers, acceptors, and interfaces, and other benefits can be designed and synthesized. Organic solar cells can be applied using thin-film deposition, such as sputtering and pulsed laser deposition, to fabricate such thin-film OPVs that generate energy. A more complete description of a suitable photovoltaic assembly can be found in concurrently pending U.S. Provisional Application No. 63 / 470,128, “Functional Glass and Artificial Glass Laminates,” filed May 31, 2023, which is incorporated herein by reference in its entirety for all purposes.

[0026] Materials and products formed from these materials are described in detail herein in accordance with certain preferred embodiments thereof, but many modifications and changes therein may be made by those skilled in the art. Therefore, the foregoing should not be construed as limiting, but rather as including such obvious modifications described above and being limited only by the spirit and scope of the following claims. For example, in one embodiment, the first embodiment is a protective structure comprising: a first layer comprising a material selected from the group consisting of polycarbonate (PC), polyethylene terephthalate (PET), thermoplastic polyurethane (TPU), acrylic and combinations thereof, having a first surface and a second surface opposite to the first surface; a hard coating on the first surface of the first layer; and a second layer comprising thermoplastic polyurethane (TPU) in contact with the second surface of the first layer.

[0027] The second embodiment is the first embodiment, wherein the structure has a thickness of approximately 0.015 inches to approximately 0.020 inches. The third embodiment is any combination of the first two embodiments, with a thickness of approximately 0.016 to 0.018 inches. The fourth embodiment is any combination of the first three embodiments, wherein the TPU includes an aliphatic TPU. The fifth embodiment is any combination of the first four embodiments, wherein the aliphatic TPU is a polyether-based aliphatic TPU.

[0028] The sixth embodiment is any combination of the first five embodiments, wherein the first layer has a thickness of approximately 0.005 to approximately 0.009 inches. The seventh embodiment is any combination of the first six embodiments, wherein the second layer has a thickness of approximately 0.008 to approximately 0.012 inches. The eighth embodiment is any combination of the first seven embodiments, wherein the protective structure is substantially optically transparent. The ninth embodiment is any combination of the first eight embodiments, wherein the protective structure has less than approximately 1% haze. The tenth embodiment is any combination of the first nine embodiments, wherein the protective structure has a light transmittance of more than approximately 90%.

[0029] The eleventh embodiment is any combination of the first ten embodiments, wherein a second layer is extruded onto the first layer. The twelfth embodiment is any combination of the first eleven embodiments, wherein the hard coating comprises a material selected from the group consisting of silicone and acrylic. A thirteenth embodiment is any combination of the first three embodiments, further including a third layer in contact with the surface of the second layer opposite the first layer, wherein the third layer includes a release liner. The 14th embodiment is any combination of the first 13 embodiments, wherein the coating is sputter-coated on the first layer. The 15th embodiment is any combination of the first 14 embodiments, wherein the first layer includes PET.

[0030] In another embodiment, a laminate is provided that includes protective structures in any combination of the first 15 embodiments. In another embodiment, a window is provided that includes a protective structure in any combination of the first 15 embodiments. In another embodiment, a shatterproof window is provided that includes a protective structure in any combination of the first 15 embodiments. In another embodiment, the first embodiment is a laminate comprising an optically transparent substrate and a protective structure bonded to the substrate. The protective structure comprises a first layer comprising a material selected from the group consisting of polycarbonate (PC), polyethylene terephthalate (PET), thermoplastic polyurethane (TPU), acrylic and combinations thereof, having a first surface and a second surface opposite to the first surface; a hard coating on the first surface of the first layer; and a second layer comprising thermoplastic polyurethane (TPU) in contact with the second surface of the first layer. The TPU layer is in contact with the optically transparent substrate.

[0031] The second embodiment is the first embodiment, wherein the substrate includes a material selected from the group consisting of glass, artificial glass, polycarbonate, acrylic, polyester, polyether, and polyurethane. A third embodiment is any combination of the first two embodiments, wherein the substrate includes glass or polycarbonate. The fourth embodiment is any combination of the first three embodiments, wherein the structure has a thickness of approximately 0.015 inches to approximately 0.020 inches. The fifth embodiment is any combination of the first four embodiments, with a thickness of approximately 0.016 to 0.018 inches. The sixth embodiment is any combination of the first five embodiments, wherein the TPU includes an aliphatic TPU. The seventh embodiment is any combination of the first six embodiments, wherein the first layer has a thickness of approximately 0.005 to approximately 0.009 inches.

[0032] The eighth embodiment is any combination of the first seven embodiments, wherein the second layer has a thickness of approximately 0.008 to approximately 0.012 inches. The ninth embodiment is any combination of the first eight embodiments, wherein the protective structure is substantially optically transparent. The tenth embodiment is any combination of the first nine embodiments, wherein the second layer is extruded onto the first layer. The eleventh embodiment is any combination of the first ten embodiments, wherein the coating comprises a material selected from the group consisting of acrylics and silicones. The twelfth embodiment is any combination of the first eleven embodiments, further including a third layer in contact with the surface of the second layer opposite the first layer, wherein the third layer includes a release liner.

[0033] The thirteenth embodiment is any combination of the first twelve embodiments, wherein the coating is sputter-coated on the first layer. The 14th embodiment is any combination of the first 13 embodiments, wherein the protection v is in contact with a first surface of the substrate, and the laminate further includes an intermediate layer in contact with a second surface of the substrate opposite to the first surface. The 15th embodiment is any combination of the first 14 embodiments, further comprising a second optically transparent substrate in contact with the intermediate layer on the opposite side of the first substrate. The sixteenth embodiment is any combination of the first fifteen embodiments, wherein the second substrate includes glass or polycarbonate. The 17th embodiment is any combination of the first 16 embodiments, wherein the laminate is ballistic.

[0034] The 18th embodiment is any combination of the first 17 embodiments, wherein the first layer includes PET. In another embodiment, a window is provided that includes laminates of any combination of the first 18 embodiments. In another embodiment, a shatterproof window is provided that includes laminates of any combination of the first 18 embodiments.

Claims

1. A first layer comprising a material selected from the group consisting of polycarbonate (PC), polyethylene terephthalate (PET), thermoplastic polyurethane (TPU), acrylic, and combinations thereof, the first layer having a first surface and a second surface opposite the first surface, A hard coating on the first surface of the first layer, and A second layer containing thermoplastic polyurethane (TPU) in contact with the second surface of the first layer. A protective structure that includes this.

2. The protective structure according to claim 1, having a thickness of approximately 0.015 inches to approximately 0.020 inches.

3. The protective structure according to claim 2, wherein the thickness is approximately 0.016 to approximately 0.018 inches.

4. The protective structure according to claim 1, wherein a second layer is extruded onto a first layer to form a single structure.

5. The protective structure according to claim 1, wherein the TPU includes aliphatic TPU.

6. The protective structure according to claim 5, wherein the aliphatic TPU is a polyether-based aliphatic TPU.

7. The protective structure according to claim 1, wherein the first layer has a thickness of about 0.005 to about 0.009 inches.

8. The protective structure according to claim 7, wherein the second layer has a thickness of about 0.008 to about 0.012 inches.

9. The protective structure according to claim 1, which is substantially optically transparent.

10. The protective structure according to claim 1, having haze of less than approximately 1%.

11. The protective structure according to claim 1, having a light transmittance of more than approximately 90%.

12. The protective structure according to claim 1, wherein the hard coating comprises a material selected from the group consisting of acrylic and silicone.

13. The protective structure according to claim 1, further comprising a third layer in contact with the surface of the second layer opposite to the first layer, wherein the third layer comprises a release liner.

14. The protective structure according to claim 1, wherein a hard coating is sputter-coated on the first layer.

15. The protective structure according to claim 1, wherein the first layer includes PET.

16. A laminate comprising the protective structure described in claim 1.

17. A window comprising the protective structure described in claim 1.

18. A shatterproof window comprising the protective structure described in claim 1.

19. Optically transparent substrates; and A laminate comprising a protective structure bonded to the substrate, The protective structure, A first layer comprising a material selected from the group consisting of polycarbonate (PC), polyethylene terephthalate (PET), thermoplastic polyurethane (TPU), acrylic, and combinations thereof, the first layer having a first surface and a second surface opposite the first surface, A hard coating on the first surface of the first layer, and A second layer containing thermoplastic polyurethane (TPU) is in contact with the second surface of the first layer and also in contact with an optically transparent substrate. A laminate containing the above.

20. The laminate according to claim 19, wherein the substrate comprises a material selected from the group consisting of glass, artificial glass, polycarbonate, acrylic, polyester, polyether, and polyurethane.

21. The laminate according to claim 19, wherein the substrate comprises glass or polycarbonate.

22. The laminate according to claim 19, wherein the protective structure has a thickness of about 0.015 inches to about 0.020 inches.

23. The laminate according to claim 22, wherein the thickness is approximately 0.016 to approximately 0.018 inches.

24. The laminate according to claim 19, wherein a second layer is extruded onto a first layer to form a single structure.

25. The laminate according to claim 19, wherein the TPU includes aliphatic TPU.

26. The laminate according to claim 19, wherein the first layer has a thickness of about 0.005 to about 0.009 inches.

27. The laminate according to claim 26, wherein the second layer has a thickness of about 0.008 to about 0.012 inches.

28. The laminate according to claim 19, wherein the protective structure is substantially optically transparent.

29. The laminate according to claim 19, wherein the hard coating comprises a material selected from the group consisting of acrylic and silicone.

30. The laminate according to claim 19, further comprising a third layer in contact with the surface of the second layer opposite to the first layer, wherein the third layer comprises a release liner.

31. The laminate according to claim 19, wherein the coating is sputter-coated on the first layer.

32. A laminate according to claim 19, wherein a protective structure is in contact with a first surface of a substrate, further comprising an intermediate layer in contact with a second surface of the substrate opposite to the first surface.

33. The laminate according to claim 32, further comprising a second optically transparent substrate in contact with an intermediate layer on the opposite side of the first substrate.

34. The laminate according to claim 33, wherein the second substrate comprises glass or polycarbonate.

35. The laminate according to claim 19, wherein the first layer includes PET.

36. The laminate according to claim 19, which is bulletproof.

37. A window comprising the laminate described in claim 19.

38. A shatterproof window comprising the laminate described in claim 19.

Images