Laminated Glass Interlayer Film with Phase Separation
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Solution Overview
Problem
Conventional interlayer films for laminated glass often have low flexural rigidity, which can lead to deflection issues in applications like automobile side doors, and struggle to maintain high sound insulation properties over time, especially when the glass thickness is reduced.
Innovation Solution
A three or more-layer interlayer film structure with specific thermoplastic resin and plasticizer compositions, where the first layer has a higher plasticizer content and a lower cloud point compared to the second and third layers, preventing excessive plasticizer transfer and enhancing both immediate and long-term flexural rigidity and sound insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-layered or multi-layered interlayer film with conventional composition is used, then sound insulating properties can be achieved, but flexural rigidity becomes low causing deflection issues
Solution Approach 1:
The invention changes the chemical composition parameters of the interlayer film by incorporating specific metal salts (alkali metal salts or alkaline earth metal salts) in controlled amounts (0.001 to 1.0 part by weight per 100 parts by weight of polyvinyl acetal resin). This compositional parameter change increases the flexural rigidity of the laminated glass while maintaining workability, resolving the contradiction between strength and ease of operation.
Solution Approach 2:
The invention creates a composite interlayer film material by combining polyvinyl acetal resin with metal salts and plasticizers. This composite structure achieves both high flexural rigidity and adequate sound insulating properties, while preventing excessive deflection during opening and closing operations.
2Weight of moving object
If glass plate thickness is reduced to decrease weight, then material usage and environmental load are reduced, but flexural rigidity becomes difficult to maintain
Solution Approach 1:
The invention compensates for the loss of flexural rigidity from thinner glass plates by changing the interlayer film composition parameters. The metal salt additives and optimized plasticizer content in the interlayer film enhance the overall rigidity of the laminated glass structure, allowing weight reduction through thinner glass while maintaining sufficient flexural rigidity.
3Object-affected harmful factors
If sound insulating layer with high plasticizer content is used, then sound insulating properties are improved, but flexural rigidity is reduced
Solution Approach 1:
The invention applies local quality by distributing different components strategically: the metal salts are incorporated throughout the polyvinyl acetal resin matrix to provide rigidity enhancement, while plasticizers are added in controlled amounts (30 to 300 parts by weight per 100 parts by weight of resin) to maintain sound insulating properties. This localized functional distribution achieves both sound insulation and flexural rigidity simultaneously.
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 interlayer film significantly enhances the flexural rigidity and sound insulation properties of laminated glass, maintaining performance even when the glass thickness is reduced, thereby improving material efficiency and environmental impact.
Implementation Method 1
Cloud point 1 determined with the use of a liquid prepared by dissolving 8 parts by weight of the thermoplastic resin for the first layer in 100 parts by weight of the plasticizer for the first layer is lower than each of Cloud point 2 determined with the use of a liquid prepared by dissolving 8 parts by weight of the thermoplastic resin for the second layer in 100 parts by weight of the plasticizer for the second layer and Cloud point 3 determined with the use of a liquid prepared by dissolving 8 parts by weight of the thermoplastic resin for the third layer in 100 parts by weight of the plasticizer for the third layer
Data Source
AI summary
An interlayer film for laminated glass includes first, second, and third layers containing a thermoplastic resin and a plasticizer. The cloud point of the first layer is lower than both the cloud point of the second layer and the cloud point of the third layer. Both the absolute value XA of a difference between the cloud point of the first layer and the cloud point of the second layer and the absolute value XB of a difference between the cloud point of the first layer and the cloud point of the third layer are 118° C. or more, and when a content of the plasticizer in the interlayer film for laminated glass relative to 100 parts by weight of the thermoplastic resin in the interlayer film for laminated glass is defined as Y, Y≤−0.16 XA+60 and Y≤−0.16XB+60.