Mixed Ion Ionomer Interlayer for Glass Laminates
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Solution Overview
Problem
Current glass laminates lack sufficient strength and adhesion to meet the increasing demands for threat resistance, particularly in applications such as hurricane-resistant and blast-resistant glass, where higher penetration resistance and enhanced adhesion are required.
Innovation Solution
A polymeric sheet with a thickness of 10 mils or greater, comprising an ionomer or ionomer blend with a specific ratio of sodium and zinc ions, providing enhanced adhesion and penetration strength, is used as an interlayer in laminated glass products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional polymeric interlayers (PVB, EVAc, PVC) are used, then ease of manufacture and optical clarity are achieved, but penetration resistance and adhesion strength are insufficient
Solution Approach 1:
The patent changes the chemical composition parameters of the interlayer by using copolyethylene ionomer resins with specific neutralization levels (10-50%) and molecular weights (10,000-100,000), achieving superior penetration resistance while maintaining manufacturability through standard lamination processes
Solution Approach 2:
The patent employs composite ionomer resins formed by neutralizing copolyethylene with mixtures of monovalent and divalent metal ions, creating a material that combines the advantages of different ion types to achieve both high strength and ease of manufacture
2Strength
If ionomer resins with high neutralization levels are used, then adhesion strength is improved, but processing difficulty and cost increase
Solution Approach 1:
The patent optimizes the neutralization level parameter to a specific range (10-50%), avoiding both low neutralization (insufficient adhesion) and high neutralization (processing difficulties), thereby achieving optimal adhesion strength with standard processing equipment and procedures
3Strength
If thicker polymeric sheets are used, then penetration resistance is enhanced, but optical clarity and weight increase
Solution Approach 1:
The patent changes the material composition parameters of the ionomer resin, specifically controlling neutralization level (10-50%) and molecular weight (10,000-100,000), which enables achieving high penetration resistance with thinner sheets while maintaining optical clarity
Solution Approach 2:
The use of composite ionomer resins with specific metal ion combinations creates a material with superior mechanical properties that provides high penetration resistance at reduced thickness, thereby maintaining optical clarity
Data Source
AI summary
The invention describes a polymeric sheet that has at least one layer that comprises an ionomer or ionomer blend that incorporates a partially neutralized alpha, beta-ethylenically unsaturated carboxylic acid component and is useful in glass laminate applications. The ionomer or ionomer blend contains one or more monovalent metal ions in an amount ranging from about 1 to about 60%, preferably about 10 to about 55%, and more preferably about 15 to about 50%, and one or more polyvalent metal ions in an amount ranging from about 40 to about 99%, preferably about 45 to about 90%, and more preferably about 50 to about 85%. This ratio range of monovalent and polyvalent metal neutralization ions provides synergistically greater adhesion to glass than found for either the monovalent or the polyvalent metal neutralization ions alone.