Laminated Glass Acoustic Dampening via Plasticizer Migration
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Solution Overview
Problem
The production of sound insulation laminated glass panes using co-extruded multilayer films is hindered by the difficulty in handling soft, highly plasticized layers and limited recyclability, leading to high production costs and phase separation issues during re-extrusion.
Innovation Solution
A method involving laminating glass panes with a thicker film containing 24-36% plasticizer and a thinner film with low or no plasticizer, where the thicker film's plasticizer migrates to the thinner film during lamination, achieving good acoustic properties without the need for co-extruded multilayer films and soft damping layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If co-extruded multilayer films with different plasticizer contents are used to achieve sound insulation properties, then acoustic performance is improved, but handling difficulty and processing complexity increase due to the softness and stickiness of highly plasticized layers
Solution Approach 1:
The patent divides the multilayer film system into separate layers that are laminated together rather than co-extruded. Each layer can have different plasticizer contents (24-36% for outer layers, lower for inner layers) without the handling difficulties of co-extruded soft layers, as each layer is processed and handled independently before final assembly
Solution Approach 2:
The plasticizer distribution is predetermined by placing layers with different plasticizer contents in specific positions before lamination. The thicker layers (24-36% plasticizer) are positioned as outer layers while thinner layers with lower plasticizer content are positioned as inner layers, establishing the desired acoustic properties before the lamination process begins
2Object-affected harmful factors
If co-extruded multilayer films are used to produce laminated glass with acoustic properties, then sound dampening is improved, but production costs increase due to complex processing requirements
Solution Approach 1:
The patent separates the production process into independent stages where layers with different plasticizer contents are manufactured separately and then laminated together. This avoids the need for complex co-extrusion equipment and processes, reducing manufacturing costs while achieving the same acoustic dampening effect
Solution Approach 2:
The patent changes the plasticizer content parameter in different layers (24-36% in outer layers, lower in inner layers) to achieve sound dampening properties. This parameter variation is achieved through simple lamination of pre-formed layers rather than complex co-extrusion, reducing production costs
3Object-affected harmful factors
If multilayer films with different plasticizer contents are co-extruded to achieve sound insulation, then acoustic performance is improved, but recyclability is limited due to phase separation during re-extrusion
Solution Approach 1:
The patent segments the multilayer structure into separately laminated layers rather than co-extruded composite material. This segmentation allows each layer to maintain its individual material properties without phase separation, enabling the laminate to be more easily recycled or reprocessed since the layers can be separated and reused independently
Solution Approach 2:
Instead of combining different plasticizer contents in a single co-extruded layer (which causes phase separation), the patent inverts the approach by creating separate layers with different plasticizer contents and laminating them together. This inversion eliminates the phase separation problem while maintaining the acoustic insulation benefits
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 approach allows for the production of laminated glass with improved acoustic properties and reduced production costs, while avoiding the handling difficulties and phase separation issues associated with co-extruded films, and enables targeted vibration behavior through controlled plasticizer distribution.
Implementation Method 1
wherein the thicker film's plasticizer migrates to the thinner film during lamination
Data Source
AI summary
The invention relates to a method for producing a laminated glass by laminating at least one film A with a glass transition temperature TA, containing a polyvinyl acetal PA and optionally at least one plasticizer WA, and at least one film B with a glass transition temperature TB, containing a polyvinyl acetal PB and at least one plasticizer WB, between two glass panes, wherein, prior to lamination, film A has a proportion of plasticizer WA of less than 24 wt%, film B has a proportion of plasticizer WB of at least 24 wt%, and film A has a thickness of no more than 30% of the thickness of film B.