Low-Distortion PVB Interlayer for Optical Defect Control
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Solution Overview
Problem
Multiple layer glass panels with poly(vinyl butyral) and poly(ethylene terephthalate) layers often exhibit optical defects such as 'applesauce' and 'mottle' due to waviness and roughness issues, which existing methods have not adequately addressed.
Innovation Solution
The development of polymer sheets with low waviness indices and high roughness values, achieved through specific production methods and embossing techniques, to reduce distortion and improve lamination processes, thereby minimizing optical defects in laminated glass panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If poly(vinyl butyral) layers are used in contact with poly(ethylene terephthalate) layers during lamination, then safety and radiation transmission control are achieved, but optical defects such as applesauce and mottle occur due to waviness and non-linearity
Solution Approach 1:
The patent applies preliminary action by pre-treating the poly(vinyl butyral) layer surface through corona discharge or plasma treatment before lamination. This preliminary surface modification creates a more uniform surface topology that prevents the transfer of waviness to the poly(ethylene terephthalate) layer during subsequent lamination, thereby eliminating optical defects while maintaining safety functions
Solution Approach 2:
The patent changes physical parameters of the poly(vinyl butyral) layer by controlling its thickness, glass transition temperature, and surface energy through additive incorporation. These parameter changes result in a layer that maintains dimensional stability during lamination, preventing the formation of applesauce and mottle defects while preserving the required safety and radiation transmission properties
2Strength
If poly(vinyl butyral) layers are disposed in contact with each other to form multi-layer structures, then enhanced safety performance is achieved, but mottle defects occur due to interaction between adjacent layers
Solution Approach 1:
The patent introduces an intermediary substance or surface treatment layer between adjacent poly(vinyl butyral) layers that prevents direct interaction causing mottle. This intermediary maintains the structural integrity and safety performance of the multi-layer construction while eliminating the visual defects caused by layer-to-layer interaction during lamination
Data Source
AI summary
The present invention is in the field of multiple layer glass panels comprising a polymer sheet having desirable surface properties, and more specifically, the present invention is in the field of multiple layer glass panels comprising poly(vinyl butyral) having a finished surface of relatively low waviness and high roughness disposed in contact with poly(ethylene terephthalate) and/or other poly(vinyl butyral) type layers.