Asymmetric Polymeric Interlayer Panels for Weight Reduction
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Solution Overview
Problem
There is a need for multiple layer glass panels that balance optimal glass thickness with sufficient strength, rigidity, and acoustic performance, particularly in automotive and aerospace applications, while minimizing weight and maintaining sound insulation properties.
Innovation Solution
The use of a multiple layer panel configuration with a first and second substrate of different nominal thicknesses, where the second substrate is at least 0.1 mm less than the first, and an interlayer comprising a first poly(vinyl acetal) resin with a specific residual hydroxyl content and a plasticizer, achieving a sound transmission loss of at least 34 dB when the ratio of the second nominal thickness to the first is between 0.23:1 and less than 1:1, and the sum of the nominal thicknesses is less than 3.7 mm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the thickness of glass sheets is reduced to decrease vehicle weight, then weight is reduced, but mechanical strength and rigidity deteriorate
Solution Approach 1:
The patent applies asymmetric glass configuration where the first glass sheet has a different thickness than the second glass sheet. Specifically, the outer glass sheet (exposed to road debris) is made thicker to maintain impact resistance and structural strength, while the inner glass sheet is made thinner to reduce overall weight. This asymmetric arrangement allows the panel to achieve both weight reduction and maintained mechanical strength by strategically placing thickness where it is most needed for structural integrity.
2Weight of moving object
If the thickness of glass sheets is reduced to decrease vehicle weight, then weight is reduced, but acoustic performance deteriorates
Solution Approach 1:
The patent employs a composite interlayer structure consisting of multiple layers with different poly(vinyl acetal) resins having distinct residual hydroxyl contents. This composite interlayer system provides enhanced acoustic insulation properties that compensate for the reduced glass thickness. The multi-layer interlayer with varying resin compositions creates acoustic damping and noise reduction capabilities, allowing the overall panel to maintain sound insulation performance even when using thinner glass sheets to reduce weight.
3Weight of moving object
If asymmetric glass configuration is used with thinner inboard panel, then weight is reduced, but sound insulation properties deteriorate
Solution Approach 1:
The patent utilizes a composite interlayer construction with multiple layers of poly(vinyl acetal) resins having different residual hydroxyl contents strategically arranged between the asymmetric glass sheets. This composite interlayer system provides enhanced acoustic damping and noise reduction properties that compensate for the thinner inboard glass panel. The varying resin compositions create acoustic impedance mismatches that reflect and absorb sound waves, maintaining effective road noise isolation despite the weight-reducing asymmetric glass configuration.
4Weight of moving object
If combined glass thickness is reduced below 3.7 mm, then weight is reduced, but deflection stiffness and impact strength deteriorate
Solution Approach 1:
The patent applies asymmetric glass configuration where the outer glass sheet (facing road debris) is made thicker to maintain impact resistance and structural strength, while the inner glass sheet is made thinner to reduce overall weight. The combined glass thickness is reduced below 3.7 mm through this asymmetric arrangement, but the structural integrity is preserved by concentrating thickness in the outer panel where it is most needed for withstanding impact loads and maintaining deflection stiffness.
Solution Approach 2:
The patent employs a composite interlayer structure with multiple layers of poly(vinyl acetal) resins having different residual hydroxyl contents that provides enhanced mechanical coupling between the glass sheets. This composite interlayer system increases the overall panel's deflection stiffness and impact strength by creating a more rigid sandwich structure, allowing the combined glass thickness to be reduced below 3.7 mm while maintaining adequate structural performance through improved load distribution and interlayer bonding.
Data Source
AI summary
Multiple layer panels including a pair of substrates and an interlayer disposed therebetween are provided. In some cases, the multiple layer panels may utilize substrates having different thicknesses, and such configurations may help reduce glass thickness and overall panel weight. However, panels of the present invention may still exhibit sufficient strength, rigidity, and acoustic performance and can be suitable for use in a wide range of automotive, aeronautical, and/or architectural applications.