Illuminable Laminated Glazing Interlayer for Uniform Light Scattering
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Solution Overview
Problem
Traditional vehicle roof lights suffer from uneven light distribution and reduced aesthetic appeal, with existing solutions like printing light scattering particles on conventional polyvinyl butyral interlayers leading to undesirable printing quality and incomplete de-airing during lamination.
Innovation Solution
Optimizing the ratio between the maximum profile valley depth (Rv) and mean particle size (D50) of light scattering particles in a polyvinyl acetal interlayer, combined with a functional layer, to achieve uniform light distribution and improved aesthetic appeal while maintaining good de-airing properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If light scattering particles are printed on conventional polyvinyl butyral interlayers with embossed surfaces, then de-airing during lamination is improved, but printing quality deteriorates due to surface roughness
Solution Approach 1:
The patent changes the surface parameters by controlling the maximum profile valley depth to a specific range (5-20 μm) and optimizes the particle size parameters (D50: 1-10 μm, D90: 10-50 μm) to achieve both good de-airing and high printing quality on conventional embossed surfaces
Solution Approach 2:
The patent applies different properties to different aspects of the surface: maintains the embossed pattern for de-airing function while controlling valley depth to ensure printing quality, creating local optimization of surface characteristics
2Manufacturing precision
If the depth of embossed trenches is reduced to improve printing quality, then printing resolution is improved, but de-airing during lamination becomes incomplete
Solution Approach 1:
The patent identifies and optimizes the critical parameter of maximum profile valley depth, setting it within 5-20 μm to simultaneously achieve sufficient de-airing capability and acceptable printing quality, avoiding the need to reduce trench depth
3Manufacturing precision
If bigger light scattering particles are used, then printing quality is improved, but aesthetic appearance deteriorates due to visible particles
Solution Approach 1:
The patent optimizes the particle size parameters by controlling D50 to 1-10 μm and D90 to 10-50 μm, achieving a balance where particles are large enough for good printing but small enough to remain imperceptible to the human eye
Solution Approach 2:
The patent uses light scattering particles that replicate the function of larger particles for printing quality while maintaining the aesthetic benefit of smaller, invisible particles through optimized size distribution
4Object-affected harmful factors
If too small light scattering particles are used, then aesthetic appearance is improved, but printing quality deteriorates due to particles appearing too deeply in trenches
Solution Approach 1:
The patent determines the optimal particle size range (D50: 1-10 μm, D90: 10-50 μm) that ensures particles are small enough for aesthetic imperceptibility but large enough to print clearly without appearing excessively deep in the embossed trenches
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 optimized ratio of Rv/D50 ensures high-quality printing and sufficient de-airing, resulting in uniform light distribution and enhanced aesthetic appeal with lower production and environmental costs.
Implementation Method 1
These particles are strategically distributed in the glazing to scatter incoming light from a light source, thereby providing a soft, diffused lighting effect across the vehicle's cabin
Data Source
AI summary
Described is an interlayer for an illuminable laminated glazing comprising a polyvinyl acetal, 22.0 to 45.0 % by weight of at least one plasticizer and a functional layer on at least one surface comprising light scattering particles with an improved ratio of maximum profile valley depth and particle size.