Transparent Laminate Edge Seal for Moisture Ingress
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Solution Overview
Problem
Transparent laminate structures, such as those used in windows and transparent armor, face issues with delamination and degradation due to moisture and solvent ingress through the edges, which can lead to reduced transparency and structural integrity, especially when exposed to environmental factors like humidity and UV light.
Innovation Solution
A transparent laminate structure with a laminated edge seal that includes a transparent interlayer and an inorganic barrier layer, which extends over the side edges to prevent the ingress of deleterious liquids and vapors, using materials like aluminum foil or ceramic elements with a polymer coating to enhance durability and resistance to chemical attacks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the transparent laminate structure uses conventional polymer interlayers without edge sealing, then the structure can be manufactured with simpler processes and lower cost, but the structure suffers from moisture and solvent ingress through edges causing delamination and loss of transparency
Solution Approach 1:
The patent applies preliminary action by extending the interlayer material over the edges of the glass and plastic layers before lamination, creating a pre-formed edge seal that prevents moisture and solvent ingress from the outset. This proactive sealing approach eliminates the need for additional post-manufacturing sealing steps while ensuring reliable protection against delamination.
Solution Approach 2:
The patent transitions from a two-dimensional interlayer (flat between layers) to a three-dimensional edge seal that extends vertically over the side edges of the laminate structure. This dimensional extension creates a barrier that blocks moisture and solvent pathways along the edges, significantly improving delamination resistance without adding complex external sealing components.
2Reliability
If the transparent laminate structure exposes edges without protection, then the manufacturing process is simpler and faster, but the structure allows ingress of water vapor and solvents that degrade the plastic layers and interlayers
Solution Approach 1:
The patent merges the interlayer function with the edge sealing function by extending the same interlayer material over the edges to perform both bonding and protective sealing roles simultaneously. This consolidation eliminates the need for separate sealing materials or processes, maintaining ease of manufacture while achieving superior chemical ingress resistance.
Solution Approach 2:
The patent employs composite material strategies by combining the interlayer material with edge coverage to create a unified sealing system. The interlayer material itself serves as the sealing barrier, integrating multiple functions into a single material system that resists moisture, solvents, and environmental degradation without requiring additional composite layers or complex material assemblies.
3Reliability
If the plastic layers are protected only by outer glass layers on faces, then the structure maintains simplicity and manufacturing ease, but the edges remain vulnerable to water vapor ingress causing crazing and loss of structural rigidity
Solution Approach 1:
The patent applies preliminary action by extending the interlayer material over the edges before lamination to create a pre-formed barrier that prevents water vapor and solvent ingress at the vulnerable edge regions. This proactive sealing protects the plastic layers from crazing and structural degradation without requiring complex post-manufacturing edge protection structures.
Solution Approach 2:
The patent transitions the protective coverage from a two-dimensional face protection (outer glass layers) to a three-dimensional edge seal that extends vertically over the side edges. This dimensional extension creates a continuous barrier that blocks moisture and solvent pathways along the edges, significantly improving structural integrity while maintaining manufacturing simplicity.
Data Source
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AI summary
A transparent laminate structure is provided that includes two transparent layers, a transparent interlayer, and an inorganic barrier layer. The two transparent layers each have an inner face and a side edge. The transparent interlayer is between and laminates the inner faces of the two transparent layers to one another. The transparent interlayer also extends over the side edges of the two transparent layers and laminates the inorganic barrier layer to at least the side edges of the two transparent layers.