Recycled PVB Interlayer Film Segmentation for Laminated Glass
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Solution Overview
Problem
Current recycling technologies for laminated glass do not effectively purify the plasticizer, limiting the use of recycled polyvinyl butyral (PVB) to low-quality applications, and the composition of recycled interlayer mixtures from different sources is often unknown, making it difficult to produce new interlayer films that meet industry safety standards for laminated glass.
Innovation Solution
A process to produce a multilayer film for laminated glass, where at least one layer is made from recycled PVB and plasticizer from recycled laminated glass, sandwiched between two layers made from virgin materials, using extrusion techniques to combine the layers, ensuring that the recycled material is not in contact with the glass, thus simplifying the recycling process and achieving higher throughput and lower costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If current recycling technologies are used to recover interlayer film from laminated glass, then the recycling process can be performed, but the plasticizer is not sufficiently purified limiting the application quality
Solution Approach 1:
The patent divides the interlayer film into multiple layers with different functions: outer layers (A) made from virgin material that contact the glass and provide adhesion, and an inner layer (B) made from recycled material that does not contact the glass. This segmentation allows the recycled material to be used without requiring complete purification of the plasticizer, thus resolving the contradiction between recycling rate and purity.
Solution Approach 2:
The patent applies different quality standards to different parts of the interlayer film. The outer layers have high purity requirements for adhesion control, while the inner layer can tolerate lower purity from recycled material. This local quality approach enables using recycled plasticizer in the inner layer without compromising overall film performance.
2Reliability
If the composition of recycled interlayer mixtures from different sources is analyzed and readjusted to meet safety standards, then the quality can be improved, but the process becomes tedious and complex
Solution Approach 1:
By segmenting the interlayer film into outer layers from virgin material and an inner layer from recycled material, the patent eliminates the need for complex composition analysis and readjustment of recycled mixtures. The virgin outer layers ensure safety standard compliance for adhesion, while the recycled inner layer can vary in composition without affecting safety.
Solution Approach 2:
The virgin outer layers act as an intermediary that ensures safety standard compliance, allowing the recycled inner layer to bypass the need for rigorous composition control. This mediator approach simplifies the recycling process by decoupling the safety requirements from the recycled material handling.
3Manufacturing precision
If recycled PVB is used in low-quality applications such as tiles and carpets, then the plasticizer purity requirement is reduced, but the application quality and value are limited
Solution Approach 1:
The patent enables recycled PVB with lower plasticizer purity to be used in high-quality applications by segmenting the film structure. The recycled material is confined to the inner layer that does not contact glass, while virgin material handles the adhesion-critical outer layers. This allows recycled PVB to be upgraded from low-quality applications to safety-critical laminated glass applications.
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 proposed process allows for the production of interlayer films that meet industry standards for glass safety, while also simplifying the recycling process, achieving higher throughput, and reducing costs, thereby enabling the use of recycled materials in higher-quality applications.
Implementation Method 1
by extrusion of the layers
Data Source
AI summary
The invention is directed to a process to produce a multilayer film for laminated glass wherein at least one of the layers comprises a mixture of polyvinyl butyral resin a plasticizer obtained from a recycled laminated glass.