Safety Glass Interlayer Extrusion with Slit Outlet Design
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Solution Overview
Problem
Existing methods for manufacturing multilayered interlayers for safety glass with colored belts face challenges such as air bubble inclusion, inadequate adhesive strength, opaque lines, and difficulty in forming larger dimensions due to probe limitations, leading to inconsistent coloring and potential breakage of equipment.
Innovation Solution
The apparatus simplifies the manufacturing process by using a guide with branching flow paths for thermoplastic resin delivery, eliminating the need for support guide pegs and allowing for the formation of larger dimensions by using a single extruding machine for outermost layers and a separate machine for the inserted layer, with outlets designed to form a slit shape for gradual thickness reduction, enabling easier and more reliable formation of large-sized colored belts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a probe without support guide pegs is used to inject coloring resin, then the colored belt can be formed, but the main raw material resin flow varies around the probe circumference causing shade variation and inconsistent coloring
Solution Approach 1:
The invention extracts and removes the support guide pegs from the probe structure. By eliminating these pegs that caused flow disturbance, the resin flows smoothly around the probe without creating shade variations, thus maintaining coloring consistency while still enabling colored belt formation.
Solution Approach 2:
Instead of using support guide pegs to stabilize the probe (conventional approach), the invention inverts the approach by designing a probe without pegs that allows free resin flow. This inversion eliminates the flow disturbance caused by the pegs while maintaining probe functionality for colored belt formation.
2Length of moving object
If a longer probe orifice is used to form larger dimension colored belts, then the colored belt size increases, but the probe bends and breaks more easily
Solution Approach 1:
The invention removes the support guide pegs that created flow resistance and mechanical stress points on the probe. This extraction allows the probe to be longer without increasing bending risk, as the resin flows smoothly around it without creating turbulence or concentrated stress.
Solution Approach 2:
The invention changes the geometric parameters of the probe design by eliminating protruding elements (pegs). This parameter change reduces the probe's susceptibility to bending while maintaining its length capability, enabling formation of larger colored belts without compromising durability.
3Strength
If roll pressing is used to fuse laminated films, then the films can be joined, but air bubbles are easily involved at the interface
Solution Approach 1:
The invention replaces the mechanical roll pressing system with a thermal adhesion system. By using heat to fuse the films together, the process eliminates the mechanical pressure that traps air bubbles, while still achieving strong adhesive bonds between the laminated films.
4Strength
If thermal adhesion is used to join transparent synthetic resin film and colored belt, then the films are fused, but opaque lines occur in the delivery direction
Solution Approach 1:
The invention optimizes the thermal adhesion parameters by controlling temperature distribution and residence time. This parameter adjustment ensures complete fusion without excessive heat that would cause degradation and opaque lines, maintaining both adhesion strength and optical uniformity in the delivery direction.
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 continuous manufacture of multilayered interlayers with a gradation structure and blurred boundary lines, enabling easier enlargement of the colored belt's width direction, reducing the risk of equipment breakage, and ensuring consistent coloring, thus facilitating the production of large-sized automobile windshields with improved visibility and reliability.
Implementation Method 1
a first and a second thermoplastic resin composition for outermost layers formation and a thermoplastic resin composition for inserted layer formation in a molten state are respectively delivered from outlets for first and second outermost layers formation and from an outlet for inserted layer formation
Implementation Method 2
the first and the second thermoplastic resin composition for outermost layers formation and the thermoplastic resin composition for inserted layer formation in a molten state are respectively delivered from outlets for first and second outermost layers formation and from an outlet for inserted layer formation
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(d)
Figure 3~4
AI summary
Provided are an apparatus and a method for manufacturing a multilayered interlayer for safety glass that allows reliable and easy formation of inserted layers having a larger coloring layer. The manufacturing apparatus 1 for manufacturing the multilayered interlayer for safety glass having a first outermost layer, an inserted layer, and a second outermost layer laminated together, wherein an outlet for the inserted layer formation 14 is provided between outlets for of the first and the second outermost layers formation 9 and 10 on an outlet side of a guide for a layer disposition 4, the outlets for the first and the second outermost layers formation 9 and 10 and the outlet for the inserted layer formation 14 have a shape of a slit, the dimension L, in a slit shape in the width direction, of the outlet for the inserted layer formation 14 is set smaller as compared with the dimension K, in a slit shape in the width direction, of the outlets for the first and the second outermost layers formation 9 and 10, the thickness of the slit is set smaller with increasing proximity to the end on at least one end of the outlet for the inserted layer formation 14 having a shape of a slit, and a metal mold for extrusion 5 is connected in a subsequent stage of the guide for a layer disposition 4.