3D Printed Interlayer for Variable Light Transmission Laminates
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Solution Overview
Problem
Existing methods for producing laminates with polymeric interlayers for variable light transmission devices, such as electrochromic and thermochromic devices, are inefficient and wasteful, particularly when using pre-formed thermoplastic sheets and requiring precise alignment and handling.
Innovation Solution
The method involves depositing a thermoplastic polymeric composition onto one substrate using 3D printing, then sandwiching it with a second substrate and laminating under heat and pressure to form a bonded laminate with a uniform interlayer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-formed thermoplastic sheets are used for laminates, then the interlayer can be easily handled and positioned, but material waste increases and alignment precision becomes difficult to achieve
Solution Approach 1:
The patent changes the physical state and application method of the thermoplastic material from pre-formed sheets to directly deposited material. The thermoplastic composition is deposited in a semi-solid or viscous state and then transformed through heating and pressing during lamination, eliminating the need for pre-cut sheets and reducing material waste while maintaining handling ease through controlled deposition parameters
Solution Approach 2:
The patent replaces the mechanical handling system (manipulating pre-formed sheets) with a deposition system that directly places thermoplastic material onto the substrate. This substitution eliminates material waste associated with cutting and positioning sheets while maintaining ease of manufacture through automated deposition processes
2Ease of manufacture
If pre-formed thermoplastic sheets are used, then the manufacturing process is simpler, but alignment precision and uniform thickness are difficult to achieve
Solution Approach 1:
The deposited thermoplastic material performs multiple functions simultaneously: it serves as the interlayer material, provides self-alignment through controlled deposition, ensures uniform thickness through precise deposition parameters, and acts as the bonding agent during lamination. This self-service approach eliminates the need for separate handling and alignment steps while maintaining process simplicity
Solution Approach 2:
The patent utilizes phase transitions of the thermoplastic material to achieve precision. The material is deposited in a semi-solid or viscous state for precise positioning, then transitions to a molten state during heating that allows flow and self-leveling for uniform thickness, and finally solidifies during cooling to lock in the precise alignment and uniform dimensions
3Productivity
If conventional lamination methods are used, then substrates of standard sizes can be processed, but adaptability to different shapes and sizes is limited
Solution Approach 1:
The patent introduces dynamics to the lamination process through the deposited thermoplastic material that can adapt its shape and coverage area. The material is deposited according to the specific geometry of each substrate, and its viscous-to-molten transition allows it to dynamically conform to different shapes and sizes, eliminating the limitations of standard-sized substrates while maintaining processing efficiency through automated deposition
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
This approach allows for the production of laminates with high optical clarity and low haze, achieving uniform thickness and eliminating waste, while also enabling the use of substrates of any shape or size.
Implementation Method 1
applying heat and pressure to melt and flow the thermoplastic composition and form the laminates
Implementation Method 2
subjecting the assembly to vacuum (or reduced pressure) to remove any trapped air or gas bubbles
Data Source
AI summary
Methods and materials to fabricate laminated devices are disclosed, particularly the laminates where the interlayer is deposited by 3d printing (or also called additive manufacturing process). In particular, emphasis is placed on the fabrication of electrooptical devices, including electrochromic, thermochromic and liquid crystal devices. In the electrochromic devices at least the electrolytic interlayer or optionally some of the other layers are deposited by this process, and for the other two the interlayer contains thermochromic and the liquid crystalline material respectively. In one embodiment printing is used to form both an interlayer and a sealant located at the perimeter of the interlayer. Laminated glass and plastic objects using this invention have many applications including their use in windows for building and transportation.