Polymer Film Surface Texture for Bubble-Free Laminated Glass
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Solution Overview
Problem
The manufacturing process of laminated glass faces challenges with polymer film adhesion and air bubble defects due to the stickiness of polymer films and gravity, leading to poor appearance and weatherability.
Innovation Solution
A polymer film with specific peak material volume (Vmp) and kurtosis (Sku) parameters, ranging from 0.15 μm3/μm2 to 1.20 μm3/μm2 and 0.73 to 10.02 respectively, is developed to minimize adhesion between piled films and ensure effective de-airing during the manufacturing process, thereby producing laminated glass with improved weatherability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If polymer films are piled on one another during manufacturing, then the production efficiency is improved, but the films adhere to each other due to gravity and stickiness making separation difficult
Solution Approach 1:
The patent applies preliminary action by pre-forming specific surface textures (concavo-convex structures with controlled Vmp and Sku parameters) on the polymer films before stacking. These pre-formed textures create air gaps and reduce contact area between adjacent films, preventing adhesion in advance and enabling easy separation during subsequent handling.
2Reliability
If the surfaces of polymer films are embossed to form textures for de-airing, then bubble formation is reduced, but the manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by optimizing specific surface texture parameters (peak material volume Vmp and kurtosis Sku within defined ranges) to achieve effective de-airing. Rather than increasing overall texture complexity, the invention modifies these key parameters to create surfaces that facilitate air escape during lamination while maintaining manufacturing simplicity.
3Ease of manufacture
If air is not sufficiently removed during manufacturing, then the production process is simplified, but the appearance and weatherability of laminated glass deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-forming specific surface textures (concavo-convex structures with controlled Vmp and Sku parameters) on the polymer films before stacking. These pre-formed textures create air gaps and reduce contact area between adjacent films, preventing adhesion in advance and enabling easy separation during subsequent handling.
Data Source
AI summary
Polymer film and laminated glass manufactured using the polymer film are provided. The polymer film has a first surface and a second surface, wherein the first surface has a peak material volume (Vmp) at a material ratio of 10% ranging from 0.15 μm3/μm2 to 1.20 μm3/μm2 and a kurtosis (Sku) ranging from 0.73 to 10.02, wherein the material ratio, peak material volume, and kurtosis are defined in accordance with ISO 25178-2:2012.