High-Molecular-Weight PVB Films for Direct Sputter Functionalization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for functionalizing polyvinyl butyral (PVB) films for laminated glass face challenges due to their softness and the need for cooling during sputtering processes, which are not economically viable.
Innovation Solution
The use of high molecular weight PVB films with a peak top molecular weight (Mp) above 150,000 g/mol, which exhibit improved stability and storage modulus during sputtering and lamination, allowing for direct functionalization without significant cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If PVB films are used for sputtering functionalization, then direct functionalization is achieved, but the films become too soft and require cooling during the process
Solution Approach 1:
The patent changes the molecular weight parameter of the PVB film from conventional levels to above 150,000 g/mol. This parameter change increases the storage modulus and thermal stability of the film, allowing it to withstand sputtering temperatures without requiring active cooling, while still enabling direct functionalization.
2Ease of operation
If PVB films with substantial plasticizer are used, then ease of processing is improved, but the films become softer and require cooling during sputtering
Solution Approach 1:
The patent changes the molecular weight parameter to above 150,000 g/mol, which compensates for the softening effect of plasticizers. The high molecular weight provides sufficient thermal stability and storage modulus even with substantial plasticizer content, eliminating the need for cooling during sputtering while maintaining processing ease.
3Reliability
If multiple film layers are used for heat shielding, then heat-shielding properties are achieved, but the device complexity increases
Solution Approach 1:
The patent combines multiple functions into a single PVB film layer. The high molecular weight PVB film can be directly functionalized with heat-shielding coatings, merging the interlayer function and heat-shielding function into one integrated component, thereby reducing the total number of layers from three to two.
Solution Approach 2:
The PVB film serves multiple functions: it acts as the interlayer material, provides the substrate for functionalization, and enables heat-shielding properties through direct coating. This multi-functionality eliminates the need for separate dedicated heat-shielding layers.
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 molecular weight PVB films maintain stability and improve adhesion during sputtering and lamination, enabling efficient production of laminated glass with functional layers.
Implementation Method 1
functionalization of PVB films by sputtering techniques
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates functionalised polyvinyl acetal films with a high molecular weight and laminated glass comprising a such functionalised films sandwiched between two sheets of glass.