Multilayer Interlayer Delamination for Stable Layer Recovery
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Solution Overview
Problem
Multilayer interlayers, particularly those with acoustic core layers, have limited recyclability due to differing physicochemical properties that cause haze during extrusion, leading to economic losses from inefficient rework processes.
Innovation Solution
A continuous process involving heating and mechanically separating a first layer from a multilayer interlayer sheet by pulling in different directions, maintaining specific angles to ensure consistent separation, using a device with unwinding, heating, and collection units to recover skin and core layers for re-use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multilayer interlayers are manually peeled for separation, then the concept of mechanical separation is demonstrated, but the process is not stable, consistent, or cost-efficient
Solution Approach 1:
The multilayer interlayer is divided into separate layers (skin layer and core layer) through mechanical delamination. The device segments the continuous multilayer sheet into individual layers that can be processed separately, enabling stable and consistent separation.
Solution Approach 2:
A delamination roller acts as an intermediary element between the multilayer sheet and the separation mechanism. The roller applies controlled mechanical force to facilitate layer separation while maintaining process stability and consistency.
2Productivity
If acoustic core layers are extruded with skin layer materials, then multilayer interlayers are formed, but the different physicochemical properties cause haze and limit recyclability
Solution Approach 1:
The delamination process recovers the skin layer and core layer as separate materials instead of discarding the entire multilayer structure. This recovery enables the materials to be reused in extrusion processes, improving recyclability and reducing waste.
Solution Approach 2:
By segmenting the multilayer interlayer into separate layers, the invention enables selective recovery and reuse of each layer. This segmentation overcomes the recyclability limitation caused by the heterogeneous composition of the original multilayer structure.
3Ease of operation
If mechanical separation is performed without angle control, then separation may occur, but the process lacks consistency and stability
Solution Approach 1:
The delamination roller is designed to rotate and apply dynamic mechanical force to the multilayer sheet. This dynamic action, combined with angle control, ensures consistent separation while maintaining ease of operation through automated process control.
Solution Approach 2:
The invention controls the delamination angle as a critical parameter to ensure consistent separation. By maintaining the angle between the delaminating surface and the multilayer sheet within a specific range (0-45 degrees), the process achieves both ease of operation and manufacturing precision.
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
Facilitates stable, efficient separation of multilayer interlayers, improving recyclability and surface smoothness, allowing recovered skin layers to be reused in extrusion processes.
Implementation Method 1
heating the multilayer sheet
Data Source
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AI summary
Processes are disclosed for separating a first layer from a remainder of a multilayer interlayer sheet, in which the multilayer sheet is heated, and thereafter the first layer is separated from the remainder of the multilayer interlayer sheet by pulling the first layer and the remainder of the multilayer interlayer sheet in different directions, in a defined orientation.