Acrylic Resin Laminate Structure for Impact and Fragment Control
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Solution Overview
Problem
Existing resin window materials lack sufficient impact resistance and tend to generate large fragments upon impact, posing a risk to equipment and human safety, especially in automotive applications where high physical performance is required.
Innovation Solution
A laminate structure comprising a first acrylic resin layer, a thermoplastic resin layer, and a second acrylic resin layer, with specific thickness ratios and Vicat softening temperatures, where the second acrylic resin layer is formed from a (meth)acrylic resin with a Vicat softening temperature of 115°C to 145°C, and optionally a third acrylic resin layer, to enhance impact resistance and control fragment size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a resin having high transparency is used for a resin window material, then transparency is improved, but impact resistance becomes insufficient
Solution Approach 1:
The invention uses a composite laminate structure comprising a first acrylic resin layer, a thermoplastic resin layer, and a second acrylic resin layer. This composite structure combines materials with different properties: the acrylic resin layers provide transparency and hardness, while the thermoplastic resin layer provides impact resistance and controls fragment scattering, thereby resolving the contradiction between transparency and impact resistance
Solution Approach 2:
The invention divides the window material into multiple functional layers: the first and second acrylic resin layers serve as transparent protective layers, while the intermediate thermoplastic resin layer serves as an impact-absorbing layer. This segmentation allows each layer to perform its specific function, with the thermoplastic layer specifically designed to control fragment size upon impact while maintaining overall transparency
2Strength
If impact resistance is improved by blending oxide compound, then impact resistance and rigidity are improved, but transparency may be affected and fragment control is insufficient
Solution Approach 1:
Instead of blending oxide compounds into a single resin, the invention uses a layered composite structure where the thermoplastic resin layer provides impact resistance and the acrylic resin layers maintain transparency. This approach achieves both high impact resistance and transparency without the need for transparency-affecting fillers
Solution Approach 2:
The invention applies different material properties to different layers: the acrylic resin layers are designed for transparency and surface hardness, while the thermoplastic resin layer is specifically designed for impact absorption and fragment control. This local differentiation of material qualities allows each layer to optimize its function without compromising the other
3Ease of manufacture
If the thickness ratio of acrylic resin layers is not controlled, then manufacturing is simplified, but impact resistance and fragment control performance deteriorate
Solution Approach 1:
The invention specifies a particular thickness ratio range (1:1.9 to 1:29) for the first acrylic resin layer to the second acrylic resin layer to optimize impact resistance and fragment control. This parameter control ensures that the thermoplastic resin layer is sufficiently thick to absorb impact energy and control fragment size, while the acrylic layers maintain adequate thickness for transparency and protection
Data Source
Figure 1~2
AI summary
Provided is an acrylic resin layer laminate having excellent impact resistance and smaller fragments generated at the time of impact. The laminate includes a first acrylic resin layer, a thermoplastic resin layer, and a second acrylic resin layer in this order, in which a ratio [T1:T2] of a thickness T1 of the first acrylic resin layer to a thickness T2 of the second acrylic resin layer is within a range of 1:1.9 to 1:29, and the second acrylic resin layer is formed of a (meth)acrylic resin having a Vicat softening temperature of 115°C or higher and 145°C or lower.