ASYMMETRICAL GLASS LAMINATES HAVING COMPOSITE INTERLAYER AND RELATED METHODS

Abstract

Various embodiments for a laminate glass article and related methods are provided. The laminated glass article includes a first and second glass layers with an interlayer positioned therebetween, comprising: a polymer core layer comprising a high modulus polymer (e.g. polyethylene terephthalate, polycarbonate, polyacrylate, and polyimide); a first low modulus material layer (e.g. first TPU or first PVB or first EVA) configured between the first layer and the polymer core layer; and a second low modulus material layer (e.g. second TPU or second PVB or second EVA) configured between the second layer and the polymer core layer.

Claims

1. A laminate glass article, comprising: a first layer of a first transparent or translucent material, the first sheet having a thickness and a first coefficient of thermal expansion (CTE) measured over a range of from 0-300 C.; a second layer of a second transparent or translucent material, the second sheet having a thickness and a second CTE; and an interlayer between the first layer and the second layer, wherein the interlayer is adhered between the first layer and the second layer; wherein the interlayer comprises a plurality of polymer layers, including: a polymer core layer comprising a high modulus polymer material; and a first low modulus material layer configured between the first layer and the polymer core layer; and a second low modulus material layer configured between the second layer and the polymer core layer.

2. The laminate glass article of claim 1, wherein the interlayer has a thickness of not greater than 2.5 mm.

3. The laminate glass article of claim 1, wherein an article surface area of at least 3 feet by 5 feet comprises of a bow of not greater than 3 mm/m when measured in accordance with ASTM C1172.

4. The laminate glass article of claim 1, wherein the high modulus polymer material is selected from the group consisting of: polyethylene terephthalate, polycarbonate, polyacrylate, polyimide, and combinations thereof.

5. The laminate glass article of claim 1, wherein the first low modulus material layer and second low modulus material layer are selected from the group consisting of: TPU, PVB, EVA, and combinations thereof.

6. The laminate glass article of claim 1, wherein the first CTE is greater than the second CTE.

7. The laminate glass article of claim 1, wherein the first CTE is 2.5 times greater than the second CTE.

8. The laminate glass article of claim 1, wherein the first CTE is greater than 7510.sup.7/ C.

9. The laminate glass article of claim 1, wherein the second CTE is less than 6010.sup.7/ C.

10. The laminate glass article of claim 1, wherein the thickness of the first layer is greater than the thickness of the second layer.

11. The laminate glass article of claim 1, wherein the second layer comprises a thickness of not greater than 1 mm.

12. The laminate glass article of claim 1, wherein the second layer comprises a thickness in the range from 0.3 mm to 1 mm.

13. The laminate glass article of claim 1, wherein the first layer is a soda lime silicate glass.

14. The laminate glass article of claim 1, wherein the second layer is an inorganic glass.

15. The laminate glass article of claim 1, wherein the second layer is an alkaline earth boro-aluminosilicate glass.

16. The laminate glass article of claim 1, wherein the interlayer comprises a thickness of 0.76 mm to 2.3 mm.

17. The laminate glass article of claim 1, wherein the polymer core has a thickness that is not greater than the thickness of the second layer.

18. The laminate glass article of claim 1, wherein the polymer core has a thickness that is not greater than half of the thickness of the second layer.

19. The laminate glass article of claim 1, wherein the first low modulus material layer and the second low modulus material layer are selected from the following thicknesses: 0.38 mm, 0.635 mm, 0.76 mm, and 1.27 mm.

20. The laminate glass article of claim 1, wherein the core polymer layer (e.g. PET) has a thickness that is selected from the group consisting of: 0.025 mm, 0.051 mm, 0.076 mm, 0.102 mm, 0.127 mm, and 0.178 mm.

21.-58. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0104] These and other features, aspects and advantages of the present disclosure are better understood when the following detailed description of the disclosure is read with reference to the accompanying drawings, in which:

[0105] FIG. 1 is a schematic depicting an embodiment of a laminate, in accordance with various embodiments of the present disclosure.

[0106] FIG. 2 is a schematic depicting an embodiment of a single glazing window including a laminate including a frame, in accordance with various embodiments of the present disclosure.

[0107] FIG. 3 is a schematic depicting an embodiment of a double pane window including a laminate, in accordance with various embodiments of the present disclosure.

[0108] FIG. 4 is a schematic depicting another embodiment of a triple pane window including a laminate, in accordance with various embodiments of the present disclosure.

[0109] FIG. 5 is a schematic depicting an embodiment of a triple pane window including two laminates, positioned as first pane and third pane, in accordance with various embodiments of the present disclosure.

[0110] FIG. 6 is a schematic depicting an embodiment of a quadruple pane window including two laminates, positioned as first pane and fourth pane, in accordance with various embodiments of the present disclosure

[0111] FIG. 7 is a schematic depicting another embodiment of a quadruple pane window including a laminate, in accordance with various embodiments of the present disclosure

[0112] FIG. 8 is a flow chart depicting an embodiment of a method of making a laminate in accordance with various embodiments of the present disclosure.

[0113] FIG. 9 is a flow chart depicting a method of installing a window having a laminate, in accordance with various embodiments of the present disclosure.

DETAILED DESCRIPTION OF THE DRAWINGS

[0114] In the following detailed description, for purposes of explanation and not limitation, example embodiments disclosing specific details are set forth to provide a thorough understanding of various principles of the present disclosure. However, it will be apparent to one having ordinary skill in the art, having had the benefit of the present disclosure, that the present disclosure may be practiced in other embodiments that depart from the specific details disclosed herein. Moreover, descriptions of well-known devices, methods and materials may be omitted so as not to obscure the description of various principles of the present disclosure. Finally, wherever applicable, like reference numerals refer to like elements.

[0115] Referring to FIG. 1, a laminate 100 is shown, having a multi-layered interlayer 120. The laminate 100 has a first glass layer 102 having a first side 104 and a second side 106 and a second glass layer 112 having a first side 114 and a second side 116. Positioned between the first glass layer and the second glass layer is the interlayer 120, which includes a first low modulus material layer (e.g. TPU layer, EVA layer, or PVB layer) 122 (having a first side 124 and second side 126); a polymer core layer 130 (having a first side 132 and a second side 134), and a second low modulus material layer (e.g. TPU layer, EVA layer, or PVB layer) 140 (having a first side 142 and a second side 144). The first side 124 of the first low modulus material layer 122 is positioned adjacent to the second side 106 of the first glass layer 102. The second side 144 of the second low modulus material layer 140 is positioned adjacent to the second side 116 of the second glass layer 112. The first side 132 of the core polymer layer 130 is positioned adjacent to the second side 126 of the first low modulus material layer 122. The second side 134 of the polymer layer 130 is positioned adjacent to the first side 142 of the second low modulus material layer 140. FIG. 1 depicts a monolithic laminate, in that each of the layers: first glass layer 102, first low modulus material layer 122; core polymer layer 130; second low modulus material layer 140; and second glass layer 112 are adhered together in an integral form (e.g. optically transparent).

[0116] FIG. 2 depicts a laminate 100 having the configuration described in FIG. 1, configured as a window 110. As shown in FIG. 2, the window is a single glazing having a first pane 148 retained (e.g. along its perimetrical edge) in a frame 108.

[0117] FIG. 3 depicts a laminate 100 having the configuration described in FIG. 1, configured as a window 110. As shown in FIG. 2, the window is a double pane window having a first pane 148 and a second pane 128. The first pane 148 is a laminate 100. The first pane 148 and second pane 128 are configured in spaced relation from one another with a seal member 118 configured between the panes (e.g. along or adjacent to a perimetrical edge). In this configuration, an air gap 150 is defined between the seal member 118, first pane 148 and second pane 128. Various gases (e.g. insulating gases) can be configured in the defined air gap 150.

[0118] FIG. 4 depicts a laminate 100 having the configuration described in FIG. 1, configured as a window 110. As shown in FIG. 4, the window is a triple pane window having a first pane 148, a second pane 128, and a third pane 136. The first pane 148 is a laminate 100. The first pane 148, second pane 128, and third pane 136 are configured in spaced relation from one another with a seal member 118 configured between the panes (e.g. along or adjacent to a perimetrical edge). In this configuration, an air gap 150 is defined between the seal member 118, first pane 148 and second pane 128 and an air gap 152 is defined between the seal member 118, the second pane 128, and the third pane 136. Various gases (e.g. insulating gases) can be configured in the defined air gap 150 and defined air gap 152.

[0119] FIG. 5 depicts an alternative embodiment for a triple pane window 100 having a laminate 100 as the first pane 148 and a laminate as the third pane 138, where the laminate is as described in FIG. 1 and the triple pane window is as otherwise described in FIG. 4.

[0120] FIG. 6 depicts a laminate 100 having the configuration described in FIG. 1, configured as a window 110. As shown in FIG. 5, the window is a quadruple pane window having a first pane 148, a second pane 128, a third pane 136, and a fourth pane 138. The first pane 148 is a laminate 100 and the fourth pane 138 is a laminate 100. The first pane 148, the second pane 128, the third pane 136, and the fourth pane 138 are configured in spaced relation from one another with a seal member 118 configured between first pane 148 and second pane 128, second pane 128 and third pane 136, and third pane 136 and fourth pane 138 (e.g. along or adjacent to a perimetrical edge). In this configuration, an air gap 150 is defined between the seal member 118, first pane 148 and second pane 128; an air gap 152 is defined between the seal member 118, the second pane 126, and the third pane 136; and an air gap 154 is defined between the seal member 118, the third pane 136 and the fourth pane 138. Various gases (e.g. insulating gases) can be configured in the defined air gap 150, the defined air gap 152, and the air gap 154.

[0121] FIG. 7 depicts an alternative embodiment for a quadruple pane window 100 having a laminate 100 as the first pane 148, where the laminate is as described in FIG. 1 and the quadruple pane window is as otherwise described in FIG. 6.

[0122] FIG. 8 provides an example method of making a laminate, in which a plurality of layers is configured together in adjacent relation to form a stack; removing air from the stack to form a curable stack; and curing the stack at a low temperature (e.g. less than 130 degrees C., less than 120 degrees C., less than 110 degrees C., or at 100 degrees C.).

[0123] FIG. 9 provides an example method of installing a window in accordance with one or more embodiments set forth herein, including configuring the IGU (window) in a fenestration opening and installing the IGU with a frame to provide an installed window. Also set out in FIG. 9 is the option for retrofit installation, in which the existing window is removed from a building to provide a fenestration opening, leaving an opening for the new window installation.

Example: Evaluation of Laminate Construction and Bow Measurement

[0124] In order to evaluate the interlayer configuration's effect on bow mitigation, an experiment was performed where five laminates were constructed and bow in the resulting laminate was measured in two directions: (1) in the diagonal across the laminate and (2) along the long edge of the laminate.

[0125] There were a total of four (4) embodiments evaluated against the control, having varying thicknesses of the first & second low modulus material layer (i.e. first TPU layer vs. the second TPU layer). The experiment utilized uniform thicknesses for various components: the first layer (soda lime glass) had a thickness of 2.1 mm; the second layer (an alkaline earth boro-aluminosilicate glass) had a thickness of 0.7 mm; and the core polymer layer (PET for embodiments A-D) had a thickness of 0.178 mm.

[0126] The same method of lamination was utilized to process all samples, in that the interlayer(s) were positioned between the two layers of glass. Air was removed via vacuum (other acceptable methods of air removal include nip rolling). Then, the interlayer was cured at elevated temperature.

[0127] The five resulting laminates, each having the same size of 1100900 mm, were evaluated for bow (1) in the diagonal across the laminate and (2) along the long edge of the laminate.

[0128] Bow was measured in accordance with ASTM C1172. More specifically, each sample was placed in a free-standing vertical position, with the longest edge resting on blocks at the quarter points. With the laminate in this position, a straightedge is then placed across the concave surface, parallel to and within 1 in. (25.4 mm) of the edge, and the maximum deviation was measured with a dial indicator. With the laminate in this position, a straightedge is then placed across the concave surface, from generally opposing corners across the diagonal of the sample, and the maximum deviation was measured with a dial indicator (diagonal bow).

[0129] The table below provides the resulting bow measurements for each of the laminates.

TABLE-US-00001 % Bow First Interlayer Second reduction layer Type/ layer Post-Lam Post-Lam vs. Control Sample Thickness, Thickness Thickness, Diagonal Long Edge (avg. vs. Description mm (mm) (mm) Bow (mm) Bow (mm) avg. control) Control 2.1 PVB/2.29 0.7 4.58 4.23 Control, N/A (non-invention) Embodiment A 2.1 TPU 1.91 0.7 1.04 1.08 75.9% PET 0.178 TPU 0.38 Embodiment B 2.1 TPU 1.27 0.7 0.75 0.80 82.3% PET 0.178 TPU 1.02 Embodiment C 2.1 TPU 1.02 0.7 1.11 1.29 72.8% PET 0.178 TPU 1.27 Embodiment D 2.1 TPU 0.38 0.7 0.86 0.94 79.6% PET 0.178 TPU 1.91

[0130] As shown in the table above, all embodiments significantly outperformed the control. Under identical processing conditions, the embodiments demonstrate about four to five times less bow compared with an approximately equal thickness of PVB. In evaluating the average bow for each sample, and in comparing the average bow of each embodiment to the bow box of the control, it's shown in the table above that all embodiments had at least a 70% improvement in bow, to over 80% improvement in bow achievable (e.g. embodiment B), as compared to the control. Three of the four embodiments (A, B, and D) measured at least a 75% reduction in bow as compared to the control, a significant improvement. Based on the four positions of the core layer in the interlayer, and proximity of the core layer to the first layer or second layer of the laminate, there did not appear to be any adverse impact on the bow mitigation of the laminate configuration.

[0131] Many variations and modifications may be made to the above-described embodiments of the disclosure without departing substantially from the spirit and various principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.