Silane Copolymer Interlayer for Moisture-Resistant Laminated Glass
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Solution Overview
Problem
Conventional laminated glass with polyvinyl butyral (PVB) interlayers is moisture-sensitive, requiring controlled storage conditions and high-temperature processing, and ethylene-vinyl acetate (EVA) interlayers with high VA content have high melt flow rates, making them unsuitable for demanding safety, insulation, and thermal applications.
Innovation Solution
A multilayer element comprising a glass or polymeric layer, an interlayer with a copolymer of ethylene and silane groups or polar comonomers, and another glass or polymeric layer, which provides superior adhesion, is moisture-insensitive, allowing for ambient storage and lower temperature processing, and can be crosslinked for improved optical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PVB interlayer material is used, then adhesion function is provided, but moisture sensitivity increases and requires controlled storage conditions
Solution Approach 1:
The patent changes the chemical composition parameters of the interlayer material by using copolymers of ethylene with silane-containing comonomers or polar comonomers, replacing PVB. This parameter change eliminates moisture sensitivity while maintaining adhesion function, as the new polymer composition is inherently resistant to moisture degradation.
Solution Approach 2:
The patent employs composite polymer materials combining ethylene with silane-containing or polar comonomers to create an interlayer that integrates both adhesion properties and moisture resistance. The composite structure provides superior performance compared to pure PVB, achieving both bonding capability and environmental stability.
2Ease of manufacture
If EVA interlayer material with high VA content is used, then processability is improved, but melt flow rate increases making it unsuitable for demanding applications
Solution Approach 1:
The patent modifies the polymer composition by using copolymers of ethylene with silane-containing comonomers or polar comonomers, which changes the rheological parameters. This results in controlled melt flow behavior that maintains processability while ensuring reliable performance in safety, insulation, and thermal applications.
Solution Approach 2:
The patent introduces specific functional groups (silane or polar comonomers) at localized positions within the polymer chain to provide both good processability and controlled melt flow. These local modifications enable the material to meet demanding application requirements without excessive melt flow.
3Reliability
If PVB interlayer is used for lamination, then adhesion is achieved, but high temperature and long duration processing is required
Solution Approach 1:
The patent changes the thermal parameters of the interlayer material by using copolymers with silane or polar comonomers that have lower melting points and better processability at reduced temperatures. This enables lamination to be performed at lower temperatures and shorter durations while maintaining reliable adhesion.
Solution Approach 2:
The patent replaces the high-temperature thermal processing mechanism required for PVB with a lower-temperature processing mechanism enabled by the copolymer composition. The silane or polar comonomer content facilitates bonding at reduced temperatures, substituting the need for high-temperature processing.
4Productivity
If conventional interlayer materials are used, then production processes are established, but production costs increase due to special storage and processing requirements
Solution Approach 1:
The patent changes the material parameters to eliminate the need for special storage conditions and high-temperature processing, thereby reducing operational costs. The copolymer composition with silane or polar comonomers allows ambient storage and lower-temperature processing, improving productivity and reducing production costs.
Solution Approach 2:
The patent adopts a simpler, more cost-effective interlayer material system that eliminates expensive special storage facilities and high-temperature processing equipment requirements. The copolymer-based interlayer can be processed with standard equipment and ambient conditions, reducing capital and operational expenditures.
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 solution offers enhanced adhesion, reduced production costs, and improved optical properties, enabling the use of the multilayer element in demanding applications such as safety glass, insulation, and thermal management without the need for special storage conditions or high-temperature processing.
Implementation Method 1
the interlayer element has an adhering function, namely prevents the first and/or second layer element from breaking up into large sharp pieces
Implementation Method 2
can be crosslinked for improved optical properties
Data Source
AI summary
The present invention relates to a multilayer element (LE), the use of the multilayer element (LE) for producing an article, an article comprising multilayer element (LE), a layer element of at least two layers, the use of the polymer composition of the invention to produce a multilayer element, as well as to a process for producing the multilayer element (LE) and an article thereof.