Laminated Glass Interlayers for Functional Device Durability
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Solution Overview
Problem
Existing laminated glass technologies face challenges in achieving good mechanical properties, safety performance, environmental resistance, and optical properties, particularly when incorporating functional devices like PDLC or SPD layers.
Innovation Solution
The use of crosslinked ethylene-vinyl acetate copolymer, polyolefin thermoplastic elastomer, or thermoplastic polyurethane elastomer as polymer layers in laminated glass, which are crosslinked to at least 50% and free of plasticizers, to enhance mechanical strength and compatibility with functional device layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional polymer interlayer materials are used in laminated glass with functional devices, then the manufacturing process is simple, but the mechanical strength and safety performance are insufficient
Solution Approach 1:
The patent uses composite polymer layers combining PVB resin with crosslinking agents (silane crosslinking or peroxide crosslinking) to create a multi-phase composite structure. This composite approach provides both the adhesive properties of PVB and the enhanced mechanical strength from crosslinked networks, resolving the contradiction between simple manufacturing and high strength requirements.
Solution Approach 2:
The patent modifies the polymer layer by introducing crosslinking degree as a critical parameter (50-90% crosslinking). This parameter change transforms the polymer from a simple adhesive layer to a high-strength structural component, enabling the laminated glass to meet both safety performance and manufacturing feasibility requirements.
2Reliability
If polymer layers with high crosslinking degree are used to improve mechanical strength, then temperature resistance and humidity resistance are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent incorporates crosslinking agents (silane or peroxide) into the PVB polymer layer during manufacturing, preparing the polymer for crosslinking in advance. The actual crosslinking occurs during the lamination heating process, so the preliminary preparation does not add separate manufacturing steps, thus improving environmental resistance without significantly increasing process complexity.
Solution Approach 2:
The patent merges the crosslinking process with the existing lamination heating process. The same heat and pressure conditions used for bonding the glass layers also activate the crosslinking reaction in the polymer layer, combining two functions into one process step and avoiding additional manufacturing complexity.
3Reliability
If plasticizers are added to polymer layers to improve flexibility and processing, then ease of manufacture is improved, but long-term stability and environmental resistance deteriorate
Solution Approach 1:
The patent extracts and removes plasticizers from the polymer layer formulation. By eliminating plasticizers entirely and relying on crosslinked PVB resin, the patent achieves long-term stability without plasticizer migration or degradation, while maintaining adequate flexibility through the elastomeric properties of crosslinked PVB.
4Reliability
If additional sealing measures are implemented to protect functional device layers, then environmental resistance is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent makes the polymer layer multi-functional by giving it both adhesive bonding function and protective sealing function through crosslinking. The crosslinked polymer layer simultaneously bonds glass layers together and creates an impermeable barrier protecting the functional device, eliminating the need for separate sealing structures and reducing overall device complexity.
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 laminated glass with improved mechanical strength, temperature resistance, humidity resistance, and optical transmittance, while maintaining the functionality of integrated functional devices like PDLC or SPD layers without the need for additional sealing.
Implementation Method 1
the polymer layers each independently comprise a polymer, which is selected from the group consisting of crosslinked ethylene-vinyl acetate copolymer, polyolefin thermoplastic elastomer and thermoplastic polyurethane elastomer
Implementation Method 2
the functional device includes but not limited to photochromic device, suspended particle device, liquid crystal device
Data Source
AI summary
A laminated glass, includes a glass plate, a polymer layer, and a functional device layer, wherein, the polymer layer is located between the glass plate and the functional device layer; the laminated glass further optionally includes another polymer layer, which is located at the other side of the functional device layer, opposite to the glass plate; the polymer layers each independently include polymer, which is selected from crosslinked ethylene-vinyl acetate copolymer, polyolefin thermoplastic elastomer, and thermoplastic polyurethane elastomer.