Organic Ink Decorated Laminate Impact Resistance
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Solution Overview
Problem
Conventional glass laminates with decorative glass/ceramic enamel frit on surfaces S2 and S4 suffer from fracture due to flexure during impact, leading to reduced stone impact resistance and increased field failures, as the enamel frit degrades the strength of the glass surfaces.
Innovation Solution
A laminate structure comprising an un-strengthened outer glass ply, a chemically strengthened inner glass ply, and a polymer interlayer, with an organic ink decoration applied on internal surfaces S2 and/or S3, replacing the decorative glass/ceramic enamel frit to enhance impact resistance without degrading the glass strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If decorative glass/ceramic enamel frit is applied on glass surfaces, then aesthetic decoration is achieved, but stone impact resistance deteriorates due to flexure-induced fracture
Solution Approach 1:
The patent extracts the decorative function from the glass surface enamel frit and relocates it to a separate polymer interlayer. This removes the harmful concentration stressors from the glass surface while preserving the aesthetic decoration in the interlayer, thereby resolving the contradiction between decoration and impact resistance.
Solution Approach 2:
The patent introduces an organic ink layer within the polymer interlayer as an intermediary decorative element. This intermediary carries the aesthetic function away from the glass surface, allowing the glass to maintain its structural integrity and impact resistance while the interlayer provides the decorative appearance.
2Shape
If enamel frit is applied on glass surfaces, then decorative appearance is achieved, but glass strength is degraded leading to increased field failures
Solution Approach 1:
The decorative appearance function is extracted from the glass surface enamel frit and transferred to the polymer interlayer containing organic ink. This extraction eliminates the reliability-degrading effect of surface enamel while maintaining the desired aesthetic appearance in the interlayer.
Solution Approach 2:
The patent creates a copy of the decorative function in the polymer interlayer using organic ink, rather than applying it directly to the glass surface. This copied decorative element achieves the same aesthetic purpose without the harmful effects on glass strength and field reliability.
3Ease of manufacture
If conventional symmetric laminate structure is used, then manufacturing simplicity is maintained, but impact failure resistance is reduced due to enamel region vulnerability
Solution Approach 1:
The patent employs an asymmetric laminate structure where the polymer interlayer with organic ink decoration is positioned specifically between the first and second glass plies, while the glass surfaces themselves remain undecorated. This asymmetric arrangement protects the vulnerable enamel region by relocating decoration to the interlayer, improving impact failure resistance while maintaining manufacturing feasibility.
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 laminate exhibits improved stone impact resistance, with a simulated break velocity of 40-95% at 75-85 mph, reducing field failures and replacements by mitigating the impact failure mode in the enamel region.
Implementation Method 1
a chemically strengthened inner glass ply
Data Source
AI summary
A decorated laminate including: an outer ply; an inner ply; a polymer interlayer between the inner ply and the outer ply; and organic ink printed decoration on one or both of internal surfaces of the laminate between the outer ply and the polymer interlayer or between the inner ply and polymer interlayer, wherein the decorated laminate has a stone impact resistance as defined herein. Also disclosed is a method of making and using the decorated laminate.