Laminated Glass Interlayer Film Structure for Weight and Rigidity
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Solution Overview
Problem
Existing lightweight laminated glasses fail to maintain desirable rigidity and resistance properties such as impact resistance, heat resistance, and moisture resistance while achieving weight reduction, especially under varying temperature conditions.
Innovation Solution
A laminated glass with an interlayer film composed of a layered structure of adhesive layers and rigid resin layers, where the adhesive layers contain a thermoplastic elastomer with alkoxysilyl groups and the rigid resin layers have a higher storage modulus, achieving a balanced density and rigidity through specific storage modulus ranges and layer configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If transparent plastic sheets are used instead of glass to reduce weight, then weight is reduced, but rigidity decreases requiring thicker sheets and hard coating layers which increases cost and complexity
Solution Approach 1:
The patent uses a composite interlayer film structure combining resin (for lightweight) and rubber particles (for rigidity and impact resistance). This composite approach allows the laminated glass to achieve both weight reduction and maintained rigidity without requiring additional hard coating layers, resolving the contradiction between weight and strength
Solution Approach 2:
The patent introduces rubber particles with specific elastic modulus into specific regions of the resin interlayer film. This local modification provides enhanced rigidity and impact resistance at critical locations while maintaining the overall lightweight characteristic of the resin-based interlayer, avoiding the need to thicken the entire sheet
2Reliability
If polyvinyl butyral interlayer film is used to maintain adhesion, then adhesion is improved, but bending rigidity decreases requiring increased overall thickness which reduces weight effectiveness
Solution Approach 1:
The patent changes the material parameters of the interlayer film by selecting resin materials with specifically controlled elastic modulus values (higher than polyvinyl butyral) and incorporating rubber particles with appropriate elastic moduli. This parameter optimization maintains both adhesion and bending rigidity, allowing thinner overall thickness while preserving weight reduction benefits
3Strength
If resin interlayer film with high Young's modulus is used to maintain bending rigidity, then bending rigidity is maintained, but impact resistance, heat resistance, and moisture resistance become insufficient under varying temperature conditions
Solution Approach 1:
The patent creates a composite interlayer film where resin provides the matrix with appropriate rigidity and rubber particles provide enhanced impact resistance and temperature adaptability. This composite structure resolves the contradiction by combining materials with complementary properties, achieving both bending rigidity and reliable performance under varying temperature and impact conditions
Solution Approach 2:
The patent strategically distributes rubber particles with specific elastic moduli within the resin interlayer film to provide localized impact absorption and temperature resistance while maintaining overall structural rigidity. This local enhancement allows the use of thinner glass sheets without compromising reliability under varying temperature conditions
4Weight of moving object
If glass thickness is reduced to achieve lightweight effect, then weight is reduced, but rigidity and resistance properties deteriorate
Solution Approach 1:
The patent uses a composite interlayer film with resin and rubber particles that compensates for the reduced glass thickness. The rubber particles provide enhanced rigidity and impact resistance that allows thinner glass sheets to maintain adequate structural performance, enabling weight reduction without sacrificing strength
Solution Approach 2:
The patent optimizes the elastic modulus parameters of the interlayer film materials (resin and rubber combinations) to compensate for reduced glass thickness. By carefully selecting materials with appropriate elastic moduli, the system maintains overall rigidity and resistance properties even with thinner glass, achieving the lightweight effect without deterioration of mechanical properties
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 results in a lightweight laminated glass with reduced mean density while maintaining or exceeding the rigidity and resistance properties of conventional glasses, suitable for various applications including automotive and building windows.
Implementation Method 1
the adhesive layers contain a thermoplastic elastomer with alkoxysilyl groups
Implementation Method 2
thermoplastic elastomer with alkoxysilyl groups
Implementation Method 3
the rigid resin layers have a higher storage modulus
Implementation Method 4
storage modulus ranges and layer configurations
Data Source
AI summary
Provided is a laminated glass where multiple glass sheets are joined via an interlayer film [J], wherein i) mean density of the laminated glass is 1.2-1.5 g/cm3 at 25° C., ii) the interlayer film [J] has layered structure comprising at least two adhesive layers [G], comprising an adhesive mainly containing a thermoplastic elastomer having an alkoxysilyl group [F]; and at least one rigid resin layer [H] positioned therebetween, iii) storage modulus of the rigid resin layer [H] is higher than that of the adhesive layer [G], iv) storage modulus of the interlayer film [J] calculated from a formula 1 or measured is 2.0×108-1.0×109 Pa at −20° C. and 1.0×108-8.0×108 Pa at 40° C.,G′=(Σiti)/(Σi(ti/G′i)) (1)where G′: calculated storage modulus of the interlayer film, G′i: storage modulus of an i-th layer of the interlayer film, ti: thickness of the i-th layer, Σi: sum of numerical values of the i-th layer.