Embossed Interlayer for Laminated Glass De-Airing
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Solution Overview
Problem
The challenge in laminated glass production is achieving efficient air removal and edge sealing during the lamination process, particularly with unplasticized high modulus polymeric interlayers, which can lead to trapped air and visual defects due to their stiffness and susceptibility to dust, requiring specific surface patterns to facilitate de-airing without premature edge sealing.
Innovation Solution
A thermoplastic interlayer sheet or film with an embossed surface pattern featuring relatively uninterrupted channels in two non-parallel directions, spaced 0.1 to 1 mm apart, with depths of 14 to 20 µm and widths of 30 to 300 µm, designed for unplasticized high modulus polymers like ethylene acid copolymers or ionomers, to facilitate efficient de-airing and reduce energy required for compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the interlayer surface is made rougher to facilitate de-airing, then air removal efficiency is improved, but the energy required for edge sealing increases
Solution Approach 1:
The invention applies different surface characteristics to different regions of the interlayer: the central area has a rough surface pattern (with Rz values of 10-50 micrometers) to facilitate de-airing, while the edge regions maintain smoother characteristics to enable efficient sealing. This localized differentiation allows each region to optimize its function without compromising the other.
Solution Approach 2:
The interlayer surface is segmented into distinct functional zones: a central de-airing zone with rough patterns and edge sealing zones with smoother surfaces. This segmentation allows independent optimization of each zone's properties, enabling effective air removal in the center while maintaining energy-efficient sealing at the edges.
2Ease of manufacture
If the interlayer surface is made smoother to facilitate edge sealing, then sealing efficiency is improved, but air removal efficiency deteriorates
Solution Approach 1:
The invention applies different surface characteristics to different regions of the interlayer: the central area has a rough surface pattern (with Rz values of 10-50 micrometers) to facilitate de-airing, while the edge regions maintain smoother characteristics to enable efficient sealing. This localized differentiation allows each region to optimize its function without compromising the other.
Solution Approach 2:
The interlayer surface is segmented into distinct functional zones: a central de-airing zone with rough patterns and edge sealing zones with smoother surfaces. This segmentation allows independent optimization of each zone's properties, enabling effective air removal in the center while maintaining energy-efficient sealing at the edges.
3Productivity
If vacuum de-airing is used to remove air at ambient temperature, then de-airing efficiency is improved, but the complexity of the lamination process increases
Solution Approach 1:
The interlayer's rough surface pattern is designed to passively facilitate air removal through its own geometric features. The channels and peaks create natural pathways for air to escape during the lamination process without requiring active vacuum systems or complex de-airing equipment, thereby simplifying the overall process while maintaining efficiency.
Solution Approach 2:
The invention replaces complex mechanical vacuum de-airing systems with a passive surface geometry solution. The rough embossed pattern on the interlayer surface creates natural channels that allow air to escape through thermal expansion and pressure differentials during heating, eliminating the need for sophisticated vacuum equipment and control systems.
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 embossed surface pattern enables effective air removal and edge sealing, reducing the likelihood of trapped air and visual defects, while minimizing energy investment for compression, thus enhancing the quality and durability of laminated glass.
Implementation Method 1
the embossed surface comprises a surface pattern that provides relatively uninterrupted channels for de-airing
Implementation Method 2
The presence of a gaseous phase within the laminate will take the form of bubbles or pockets of gas between the interlayer and glass interface. These are generally objectionable for end-use applications where the laminate functions as a transparent article... Autoclaving is a step typically utilized in the production of laminated glass using a combination of heat and pressure to hasten the dissolution of any residual air (gaseous component) within the laminate assembly.
Implementation Method 3
Thermoplastic interlayers are typically heated during the lamination process to soften the interlayer and facilitate adhesion to glass or plastic material.
Data Source
Figure 1A~1C
Figure 2
Figure 3
AI summary
This invention relates to thermoplastic interlayer sheets or films for laminated safety glass with superior vacuum de-airing at elevated temperatures and superior tacking and edge sealing properties. The sheeting has an embossed surface pattern on at least one of the surfaces, which provides relatively uninterrupted channels for de-airing in at least two non-parallel directions, wherein the channels are spaced about 0.1 to about 1 mm apart and have a depth of less than about 25 μm and a width of about 30 to about 300 μm.