Laminated Glazing Interlayer Roughness for Printing and De-Airing
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Solution Overview
Problem
Traditional vehicle roof lights suffer from uneven light distribution and reduced aesthetic appeal due to the integration of light scattering particles on conventional polyvinyl butyral interlayers with uneven surfaces, leading to poor printing quality and incomplete de-airing during lamination.
Innovation Solution
An interlayer for laminated glazing with a polyvinyl acetal and 22.0 to 45.0% plasticizer, featuring a functional layer with light scattering particles, has a balanced mean profile element width (Rsm) of 200 to 800 µm and maximum roughness (Rz) of 15 to 50 µm, allowing for improved printing quality and complete de-airing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If light scattering particles are printed onto conventional polyvinyl butyral interlayer with embossed surface pattern, then de-airing during lamination is improved, but printing quality and illumination uniformity deteriorate
Solution Approach 1:
The invention changes the surface parameters by controlling the embossing pattern dimensions - specifically setting the groove width to 5-20 µm and spacing to 200-800 µm. This parameter optimization allows the surface to provide adequate de-airing channels while maintaining sufficient flatness for high-quality particle printing, thus resolving the contradiction between ease of manufacture and manufacturing precision.
2Manufacturing precision
If surface roughness Rz is reduced to improve printing quality, then illumination uniformity is improved, but de-airing capability during lamination deteriorates
Solution Approach 1:
The invention optimizes the embossing pattern parameters to achieve a balance: groove width of 5-20 µm and spacing of 200-800 µm. This creates an Rz value range of 15-50 µm that provides adequate de-airing channels while maintaining sufficient flatness for high-quality particle printing, thus resolving the contradiction between printing quality and de-airing capability.
3Ease of manufacture
If conventional embossed interlayer is used, then de-airing is achieved, but light distribution uniformity and aesthetic appeal deteriorate
Solution Approach 1:
The invention changes the embossing pattern parameters to groove width 5-20 µm and spacing 200-800 µm, creating an optimized surface structure that provides adequate de-airing while maintaining sufficient flatness for uniform particle distribution. This results in Rz values of 15-50 µm that enable both effective de-airing and homogeneous light scattering, resolving the contradiction between ease of manufacture and illumination quality.
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 solution provides uniform light distribution, enhanced aesthetic appeal, and reduced production and raw material costs while maintaining optical quality and environmental benefits.
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 surface roughness.