Composite Pane With IR and Low-E Coatings for Recycled Interlayers
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Solution Overview
Problem
Existing laminated glazings using recycled thermoplastic materials suffer from inconsistent adhesion and degradation due to varying chemical compositions, leading to reduced safety and lifespan, particularly in vehicle applications where long-term performance is critical.
Innovation Solution
A composite pane design incorporating a thermoplastic interlayer with at least 10% recycled material, combined with an IR reflective coating between the panes and a low emissivity coating on the inner pane, ensuring consistent adhesion and protection from solar radiation, while maintaining thermal management and safety standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If recycled thermoplastic materials are used in laminated glazing, then environmental sustainability and cost are improved, but adhesion consistency and chemical stability deteriorate due to varying compositions
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the thermoplastic interlayer through controlled incorporation of recycled materials (10-100% content) while adjusting formulation parameters to maintain adhesion properties. This allows utilization of recycled materials while compensating for composition variability to ensure reliable adhesion to glass panes.
Solution Approach 2:
The patent uses composite materials by creating a hybrid interlayer system that combines recycled thermoplastic materials with virgin thermoplastic materials or adhesion promoters. This composite approach leverages the cost and environmental benefits of recycled materials while the virgin components ensure consistent adhesion performance, resolving the contradiction between waste utilization and reliability.
2Loss of substance
If recycled thermoplastic materials with varying chemical compositions are used, then environmental impact is reduced, but lifespan and safety performance deteriorate
Solution Approach 1:
The patent modifies chemical composition parameters of the recycled thermoplastic interlayer by adjusting plasticizer content, polymer ratio, and additive packages to ensure long-term stability. These parameter optimizations prevent degradation and maintain mechanical properties over the service lifespan, enabling use of recycled materials while ensuring durability.
Solution Approach 2:
The patent applies beforehand cushioning by incorporating stabilizers, antioxidants, and adhesion promoters into the recycled thermoplastic formulation before lamination. These preventive additives cushion against future degradation from UV exposure, heat, and moisture, ensuring long-term lifespan and safety performance despite using recycled materials.
3Object-affected harmful factors
If tinted thermoplastic interlayer is used to achieve low light transmittance, then solar protection is improved, but adhesion and cohesive strength deteriorate due to pigment degradation
Solution Approach 1:
The patent changes the parameters of solar protection by using IR-reflective coatings instead of traditional organic pigments. This physical/optical approach (coating deposition) provides solar protection without the chemical degradation issues of dyes, maintaining both protection performance and material strength over time.
Solution Approach 2:
The patent replaces the chemical mechanism (organic pigments absorbing UV) with a physical mechanism (IR-reflective coatings blocking infrared radiation). This substitution eliminates the degradation pathway of organic dyes while maintaining solar protection, thereby preserving cohesive strength and adhesion.
4Illumination intensity
If multiple coatings are added to achieve required light transmittance and sun protection, then optical performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies multi-functionality by designing the IR-reflective coating to simultaneously provide solar heat rejection, glare reduction, and aesthetic appearance. This single multi-functional coating replaces what would otherwise require multiple separate layers (tint, reflective layer, protective layer), simplifying the overall structure while achieving comprehensive optical performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite pane achieves a light transmittance of 1 to 10%, with external reflectance below 13% and internal reflectance below 8%, ensuring long-term durability and safety, meeting automotive standards and reducing heat absorption.
Implementation Method 1
a sun protection coating (4) between the outer pane (1) and the inner pane (2), which sun protection coating reflects or absorbs mainly radiation outside of the visible spectrum of the solar radiation, in particular infrared radiation
Implementation Method 2
a thermal-radiation-reflecting coating (5) (low-E coating), characterized in that the composite pane has a transmittance index A of 0.02 to 0.08
Data Source
AI summary
A composite pane having an IR reflective coating and a low emissivity coating and a method to provide for the pane and to uses thereof.