High Flow PVB Interlayer for Warped Glass Lamination
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Solution Overview
Problem
Existing multiple layer glass panels face issues with delamination and bubbling, particularly when using warped or wavy glass substrates, due to inefficient de-airing and increased interlayer thickness or flow, which leads to problems like blocking, creep, and decreased mechanical strength.
Innovation Solution
A high flow interlayer comprising a poly(vinyl butyral) resin with a specific molecular weight range and plasticizers, combined with an anti-blocking agent, to achieve improved flow without sacrificing mechanical strength or increasing thickness, thereby reducing delamination and bubbling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If interlayer thickness is increased to prevent delamination and bubbling, then bonding effectiveness is improved, but blocking and creep increase
Solution Approach 1:
The patent changes the molecular weight parameter of the poly(vinyl butyral) resin to a specific range (100,000 to less than 180,000 Daltons) and adjusts plasticizer content to achieve optimal flow characteristics. This allows the interlayer to have sufficient flow to prevent delamination and bubbling while maintaining appropriate viscosity to reduce blocking and creep, thus resolving the contradiction between bonding effectiveness and compositional stability.
2Reliability
If interlayer flow is increased to improve de-airing and bonding, then delamination and bubbling are reduced, but mechanical strength decreases
Solution Approach 1:
The patent optimizes the molecular weight parameter of the poly(vinyl butyral) resin to a specific range (100,000 to less than 180,000 Daltons) and adjusts plasticizer content to achieve the balance between flow and strength. This controlled parameter change enables sufficient flow for effective de-airing while maintaining the mechanical strength required for structural integrity.
Solution Approach 2:
The patent creates a composite interlayer material combining poly(vinyl butyral) resin with specific molecular weight characteristics and plasticizers. This composite formulation achieves the dual benefit of improved flow for de-airing efficiency while maintaining mechanical strength, resolving the contradiction between these two properties.
3Productivity
If interlayer thickness is reduced to降低成本 and improve efficiency, then cost and productivity are improved, but bonding effectiveness may deteriorate
Solution Approach 1:
The patent changes the molecular weight parameter of the poly(vinyl butyral) resin to a specific range (100,000 to less than 180,000 Daltons) and optimizes plasticizer content to enhance flow characteristics. This allows thinner interlayers to achieve sufficient flow and bonding effectiveness during lamination, thereby reducing material costs and improving manufacturing efficiency without sacrificing reliability.
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 high flow interlayer effectively bonds warped substrates with reduced creep and blocking, maintaining structural integrity and optical clarity, while allowing for thinner interlayers that are cost-effective and efficient to produce.
Implementation Method 1
a surface roughness, Rz, as formed by melt fracture of greater than or equal to about 25 μm
Data Source
AI summary
An interlayer comprised of a high flow, low molecular weight thermoplastic resin, and at least one plasticizer is disclosed. The use of a high flow, low molecular weight thermoplastic resin, and a plasticizer creates synergy allowing the flow of the interlayer to be increased without sacrificing other characteristics typically associated with an increased flow (e.g., increased blocking, decreased mechanical strength, and decreased manufacturing capability). In this regard, the high flow, low molecular weight thermoplastic resin provides a flow improvement, resulting in a high flow interlayer. As a result, a thinner interlayer can be utilized in forming multiple layer panels because the resulting thinner interlayer has improved flow properties.