Cross-linked Acid Copolymer Interlayer for Glass Laminates
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Solution Overview
Problem
There is a need to improve the physical and mechanical properties of interlayers in safety laminates, particularly to enhance their clarity, mechanical integrity, and resistance to break while maintaining processability and long-term stability, which existing ethylene acid copolymer and ionomer interlayers do not adequately provide.
Innovation Solution
A glass laminate with an interlayer sheet composed of an acid copolymer composition that includes an ethylene copolymer with copolymerized units of α,β-unsaturated carboxylic acids and a hydroxyl-containing crosslinking agent, where the carboxylic acid groups are optionally neutralized to form carboxylate salts, and the crosslinking agent reacts with the ethylene copolymer to form cross-links, improving mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If peroxides are used to crosslink ethylene vinyl acetate copolymers, then mechanical strength is improved, but gel formation and material degradation occur
Solution Approach 1:
The patent changes the chemical parameters of the crosslinking system by replacing peroxide with metal carboxylates (such as zinc stearate) and adding organometallic catalysts (such as diethylaluminum monochloride). This parameter change in the crosslinking mechanism allows achieving mechanical strength improvement without the harmful gel formation and degradation associated with peroxide crosslinking.
Solution Approach 2:
The patent introduces metal carboxylates and organometallic compounds as intermediary substances that mediate the crosslinking process. These intermediaries enable controlled crosslinking of ethylene acid copolymers without causing the uncontrolled gel formation that occurs with direct peroxide crosslinking, thus maintaining material stability while improving strength.
2Strength
If cross-linking is performed to improve mechanical properties, then tensile strength and elongation are enhanced, but processability may deteriorate
Solution Approach 1:
The patent incorporates the crosslinking agent and catalyst into the polymer composition before processing, but the actual crosslinking reaction is activated only under specific processing conditions (temperature and pressure). This preliminary preparation allows the material to maintain good processability during manufacturing while achieving the desired crosslinked structure and enhanced tensile strength in the final product.
Solution Approach 2:
The patent utilizes changes in temperature and pressure parameters during processing to control the timing and extent of crosslinking. By carefully managing these parameters, the material remains processable during manufacturing operations and then undergoes controlled crosslinking to achieve enhanced mechanical properties without compromising ease of manufacture.
3Stability of the object's composition
If cross-linking is performed to improve mechanical properties, then creep resistance is enhanced, but material degradation may occur
Solution Approach 1:
The patent employs metal carboxylates and organometallic compounds as intermediary substances that facilitate controlled crosslinking without causing material degradation. These intermediaries enable the formation of a stable crosslinked network that improves creep resistance while maintaining material integrity, avoiding the degradation issues associated with conventional peroxide crosslinking methods.
Solution Approach 2:
The patent controls the crosslinking process by adjusting parameters such as temperature, pressure, and catalyst concentration to achieve optimal creep resistance without exceeding thresholds that would cause material degradation. This precise parameter control ensures enhanced long-term stability while preserving material integrity.
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 cross-linked acid copolymer composition exhibits enhanced tensile strength, elongation, and creep resistance, making it suitable for advanced safety laminates with improved mechanical integrity and optical clarity.
Implementation Method 1
Cross-linking occurs when chemical bonds are formed between polymeric moieties, producing polymeric networks that can enhance the overall strength of the crosslinked material.
Data Source
AI summary
Provided herein are glass laminates, preferably safety glass laminates, that comprise a polymeric interlayer sheet formed of an acid copolymer composition. The acid copolymer composition comprises an ethylene acid copolymer which, in turn, comprises copolymerized units of ethylene, about 5 to about 90 wt % of copolymerized units of a first α,β-unsaturated carboxylic acid having 3 to 10 carbon atoms; and optionally about 2 to about 40 wt % of copolymerized units of a derivative of a second α,β-unsaturated carboxylic acid having 3 to 10 carbon atoms. Optionally, a portion of the carboxylic acid groups of the copolymerized units of the ethylene acid copolymer are neutralized to form carboxylate salts. The acid copolymer composition also includes a hydroxyl-containing crosslinking agent and may also include an adjuvant. The glass laminates have superior resistance to creeping due to the properties of the acid copolymer composition, which may optionally be cross-linked.