Polymer Interlayer with Blocked Core for Bubble Prevention
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Solution Overview
Problem
Laminated multiple layer glass panels often develop optical defects such as bubbles during manufacturing, particularly at the edges and trim areas, which affect their optical, mechanical, and acoustic performance.
Innovation Solution
A polymer interlayer with a non-core portion extending from the edge, where the core layer is absent, is used to prevent bubble formation, maintaining the interlayer's optical, mechanical, and acoustic characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multilayer interlayer with soft core layer and stiff skin layers is used, then sound insulation properties are improved, but optical defects such as bubbles form at edges and trim areas
Solution Approach 1:
The interlayer is segmented into distinct functional zones: a first interlayer portion at the edge/trim area containing only stiff skin layers, and a second interlayer portion in the central area containing the soft core layer between skin layers. This segmentation allows each zone to be optimized for its specific function without compromising the other.
Solution Approach 2:
Different portions of the interlayer are assigned different structural qualities: the edge portion has a single-layer stiff structure optimized for manufacturing precision and bubble prevention, while the central portion has a multilayer structure with soft core optimized for sound insulation. This local differentiation resolves the contradiction by providing appropriate properties in each location.
2Reliability
If the interlayer structure is optimized for acoustic performance, then sound transmission loss is improved, but bubble formation occurs during manufacturing
Solution Approach 1:
The soft core layer is extracted or removed from the edge and trim portions of the interlayer, leaving only the stiff skin layers in these areas. This extraction eliminates the source of bubble formation in problematic regions while preserving the full multilayer structure with soft core in central areas where acoustic performance is prioritized.
3Reliability
If a uniform multilayer structure is used throughout the interlayer, then acoustic properties are maximized, but manufacturing complexity and defect risk increase
Solution Approach 1:
The interlayer is divided into segments with different structural complexities: a simplified single-layer structure at edges and a full multilayer structure in the center. This segmentation reduces overall manufacturing complexity and defect risk while maintaining acoustic properties in the critical central viewing area.
Data Source
AI summary
A polymer interlayer that resists formation of optical defects. The polymer interlayer comprises a first polymer layer, a second polymer layer, and a third polymer layer. The first polymer layer is positioned between the second polymer layer and the third polymer layer. The first polymer layer has a glass transition temperature of less than about 20° C. and the second and third polymer layers each have a glass transition temperature of more than about 25° C. The polymer interlayer has an edge. The first polymer layer is not present within a portion of the polymer interlayer. The portion of the polymer interlayer extends a distance X from the edge of the polymer interlayer, with the distance X being between 0.2 and 40 cm.