Interlayer Film Bonding via Reduced-Pressure Heating
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Solution Overview
Problem
The production of transparent glass laminates using interlayer films requires high-temperature and high-pressure autoclave treatment, necessitating expensive and large equipment, which increases production costs and is not easily scalable.
Innovation Solution
An interlayer film containing a polyvinyl acetal resin with a specific composition of unsaturated fatty acid alkyl esters and diester compounds, allowing for bonding with glass sheets under reduced-pressure heating conditions, eliminating the need for autoclave treatment and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-temperature and high-pressure autoclave treatment is performed to bond interlayer film and glass sheets, then bonding strength and transparency are improved, but production cost increases due to expensive and large equipment requirements
Solution Approach 1:
The invention changes the chemical composition parameters of the interlayer film by incorporating specific plasticizers (polyalkylene glycol in 30-70 wt% and polyol in 30-70 wt%) into the polyvinyl butyral resin matrix. This compositional parameter change enables the film to achieve adequate bonding strength under milder heating conditions (80-120°C) without requiring high-pressure autoclave treatment, thereby eliminating the need for expensive large-scale autoclave equipment and reducing production costs.
2Illumination intensity
If high-temperature and high-pressure autoclave treatment is used to ensure transparency, then optical quality is improved, but equipment complexity and investment increase
Solution Approach 1:
The invention modifies the chemical parameters of the interlayer film composition by incorporating specific plasticizers that enable bonding at lower temperatures (80-120°C). This parameter change allows the film to maintain transparency and optical quality without requiring high-temperature autoclave treatment, thereby simplifying the equipment requirements from complex high-pressure autoclaves to simpler heating and pressing devices.
3Strength
If conventional plasticizer blends are used in interlayer film, then adhesion is improved, but high-temperature autoclave treatment is still required to eliminate air bubbles and achieve transparency
Solution Approach 1:
The invention creates a composite plasticizer system combining polyalkylene glycol (30-70 wt%) and polyol (30-70 wt%) within the polyvinyl butyral resin matrix. This composite plasticizer blend provides both adequate adhesion to glass sheets and enables processing at lower temperatures (80-120°C), eliminating the need for high-temperature autoclave treatment while maintaining film transparency and eliminating air bubbles.
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 enables the production of transparent glass laminates without residual air bubbles and with improved transparency and bonding strength, using milder conditions and reducing equipment costs by eliminating the need for autoclave treatment.
Implementation Method 1
bonding with glass sheets under reduced-pressure heating conditions
Implementation Method 2
bonding strength
Data Source
AI summary
Disclosed herein are an interlayer film for glass laminate, which contains a polyvinyl acetal resin and can be easily bonded to glass sheets to produce a glass laminate having high transparency, and a glass laminate using such an interlayer film. The interlayer film for glass laminate includes 100 parts by weight of a polyvinyl acetal resin and 40 to 75 parts by weight of a plasticizer, wherein 4 to 40 wt% of the plasticizer is composed of an unsaturated fatty acid alkyl ester having 16 to 20 carbon atoms.