Direct Embossing Polymer Melt Sheet for Laminated Glass
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Solution Overview
Problem
Existing methods for manufacturing multiple layer glass panels face inefficiencies in embossing polymer interlayers, leading to increased energy costs, space requirements, and decreased output due to multiple cooling and reheating steps, which result in blocking issues and inadequate deairing, particularly when polymer interlayers stick to embossing rollers and require separate embossing stages.
Innovation Solution
A continuous, online single-stage embossing process where the polymer melt sheet is embossed immediately after extrusion and then cooled, using temperature-controlled engraved rollers to create an embossed polymer interlayer sheet with a surface roughness of 10 to 90 microns, maintaining embossed surface retention and permanence even at elevated temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the polymer interlayer sheet is cooled before embossing, then blocking is prevented, but the embossing process requires additional cooling and reheating steps increasing energy costs and time
Solution Approach 1:
The polymer interlayer sheet is embossed immediately after extrusion while still in melt state, before cooling occurs. This preliminary embossing action eliminates the need for subsequent cooling and reheating steps, reducing energy consumption while preventing blocking through the embossed surface structure
Solution Approach 2:
The patent changes the temperature parameter by maintaining the polymer in melt state during embossing rather than cooling it first. This parameter change allows direct embossing without blocking, as the embossed surface structure prevents adhesion even in melt state, eliminating energy-intensive cooling and reheating cycles
2Object-affected harmful factors
If the polymer interlayer sheet is cooled before embossing, then blocking is prevented, but the manufacturing time and process complexity increase
Solution Approach 1:
Embossing is performed as a preliminary action immediately after extrusion while the polymer is still molten, consolidating multiple operations into one step. This eliminates the sequential cooling-then-embossing process, reducing manufacturing time and process complexity
Solution Approach 2:
The extrusion and embossing operations are merged into a single continuous process step. The polymer is extruded and embossed immediately without intermediate cooling, combining what were previously separate sequential operations into one integrated process, thereby reducing time and complexity
3Object-affected harmful factors
If multiple embossing stages are used, then blocking and de-airing are improved, but the device complexity and space requirements increase
Solution Approach 1:
A single embossing stage performs the blocking-prevention function immediately after extrusion, making additional embossing stages unnecessary. This preliminary embossing action creates sufficient surface structure to prevent blocking without requiring multiple sequential embossing operations
Solution Approach 2:
The patent extracts and eliminates redundant embossing stages from the process, retaining only the essential single embossing operation performed immediately after extrusion. This removal of unnecessary steps simplifies device complexity while maintaining blocking prevention effectiveness
4Object-affected harmful factors
If multiple embossing stages are used, then blocking and de-airing are improved, but the space requirements and production costs increase
Solution Approach 1:
Multiple embossing stages and their associated cooling/reheating equipment are merged into a single embossing operation performed immediately after extrusion. This consolidation reduces the physical space required for multiple separate embossing stations and auxiliary equipment
Solution Approach 2:
The single preliminary embossing stage performed immediately after extrusion eliminates the need for subsequent embossing stages, reducing the total equipment footprint and space requirements while maintaining effective blocking prevention
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
This process reduces energy costs, space requirements, and improves efficiency by allowing simultaneous embossing of both sides in a single stage, enhancing embossed surface retention, permanence, and reducing mottle and stack sticking issues, while maintaining optical clarity and adhesion properties.
Implementation Method 1
temperature-controlled engraved rollers
Implementation Method 2
then cooled
Implementation Method 3
cooled, using temperature-controlled engraved rollers to create an embossed polymer interlayer sheet
Data Source
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AI summary
A continuous single-stage embossing station comprised of two (2) temperature controlled engraved rollers which is located immediately after the extrusion die in the manufacturing process for multi-layer laminated glass panels and allows for dual simultaneous embossment of both sides of a polymer melt sheet and produces a polymer interlayer sheet with increased permanence, embossed retention values and decreased incidence of mottle and stack sticking peel force values. Also disclosed herein is an embossed polymer interlayer sheet with a first side, a second side and an embossed surface on at least one of the sides, with a surface roughness Rz of 10 to 90 microns on the embossed surface, a permanence of greater than 95% when tested at 100°C for five (5) minutes and an embossed surface retention of greater than 70% when tested at 140 °C for five (5) minutes.