Embossed Polymeric Interlayers for Uniform Surface Roughness
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Solution Overview
Problem
The production of safety glass and multiple layer panels faces challenges in achieving consistent surface roughness and de-airing performance due to non-uniform thickness and conventional embossing techniques, which can result in air bubbles, optical distortion, and mottle issues.
Innovation Solution
A polymeric sheet with tapered and flat zones, featuring a wedge angle of at least 0.10 mrad for the tapered zones and less than 0.05 mrad for the flat zones, is embossed to create a surface with uniform Rz values, ensuring effective de-airing and optimal optical and acoustic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional embossing techniques are used on non-uniform thickness interlayers, then de-airing performance is improved, but surface roughness uniformity deteriorates
Solution Approach 1:
The patent applies different surface structures to different regions of the interlayer. The leading end portion has a first surface structure with specific roughness characteristics, while the trailing end portion has a second surface structure with different roughness characteristics. This local differentiation allows each region to be optimized for its specific function during the lamination process, resolving the contradiction between de-airing performance and surface uniformity.
Solution Approach 2:
The interlayer surface is segmented into distinct zones with different roughness properties. By dividing the surface into a leading end portion and a trailing end portion, each with tailored surface characteristics, the patent enables simultaneous optimization of air escape pathways and visual appearance, resolving the technical contradiction between functional performance and aesthetic quality.
2Reliability
If surface roughness is increased to improve de-airing, then air removal is enhanced, but optical distortion and mottle increase
Solution Approach 1:
The patent implements different surface roughness levels in different spatial locations of the interlayer. The leading end portion has higher roughness to facilitate air escape, while the trailing end portion has lower roughness to minimize optical distortion and mottle. This spatial differentiation of surface quality resolves the contradiction between air removal efficiency and optical clarity.
3Reliability
If embossing is applied to non-uniform thickness interlayers, then de-airing channels are created, but extensive non-uniformities and undesirable roughness are caused
Solution Approach 1:
The patent creates different surface structures at different locations of the interlayer to account for the non-uniform thickness distribution. The leading end portion receives embossing treatment optimized for de-airing, while the trailing end portion receives treatment optimized for surface uniformity. This localized approach resolves the contradiction between creating effective de-airing channels and maintaining surface uniformity.
Data Source
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AI summary
Embossed polymer sheets and interlayers having at least one tapered zone are provided. The roughness of the embossed portion of the sheets and interlayers may be substantially uniform. Methods and systems for producing such interlayers are also described herein and may utilize at least one pair of rollers oriented substantially parallel to one another. When used in multiple layer panels, such as safety glass laminates, the embossed tapered interlayers described herein exhibit excellent optical performance, as indicated by the low haze and high clarity of the resulting panels.