Glazing

Abstract

A laminated glazing comprises two plies of glass having an interlayer structure laminated therebetween. The interlayer structure comprises a first sheet of an interlayer material framing a suspended particle device film incorporated therein. The interlayer material is chosen to minimize the migration of the components of the interlayer material into the suspended particle device film. Preferably, the interlayer material does not contain plasticizers, or contains a plasticizer which does not diffuse into the suspended particle device film structure.

Claims

1. A laminated glazing comprising first and second plies of glass having an interlayer structure laminated therebetween, the interlayer structure comprising a first sheet of an interlayer material having a hole therein, the first sheet of interlayer material being directly laminated between a second and a third sheet of an interlayer material, there being a suspended particle device film positioned in the hole in the first sheet of interlayer material, the suspended particle device film being coplanar with the first sheet of interlayer material and being framed by the first sheet of interlayer material, wherein the interlayer material components of the first sheet do not comprise a plasticizer, or comprise a plasticizer that does not migrate into the suspended particle device film, wherein the first sheet of interlayer material is one of ethylene vinyl acetate copolymer, polyurethane, or poly vinyl chloride.

2. The laminated glazing of claim 1, wherein the suspended particle device film comprises a coloured substrate.

3. The laminated glazing of claim 1, further comprising a poly ethylene terephthalate substrate having a heat reflective solar control coating and a fifth sheet of an interlayer material, interposed between the fourth sheet of interlayer material and the second ply of glass.

4. The laminated glazing of claim 1, wherein at least one sheet of interlayer material has solar control properties.

5. The laminated glazing of claim 1, further comprising at least one of a solar control, heat reflective, low-emissivity, hydrophobic or hydrophilic coating.

6. The laminated glazing of claim 1, further comprising a third ply of glass, separated from the second ply of glass by an air gap.

7. The laminated glazing of claim 1, wherein the thickness of the suspended particle device film is the same as the first layer of interlayer material.

8. The laminated glazing of claim 1, wherein at least one of the second and third sheets of interlayer material is in direct contact with and co-extensive with one of the first and second plies of glass.

9. The laminated glazing of claim 1, wherein a peripheral edge of the suspended particle device film is in direct contact with an interior edge of the first sheet of interlayer material, the interior edge of the first sheet of interlayer material defining the hole in the first sheet of interlayer material.

10. The laminated glazing of claim 1 further comprising a fourth sheet of interlayer material and a barrier layer, the barrier layer being between the third and fourth sheets of interlayer material.

11. The laminated glazing of claim 10, wherein the barrier layer is poly ethylene terephthalate.

12. The laminated glazing of claim 10, wherein the suspended particle device film comprises a coloured substrate.

13. The laminated glazing of claim 10, further comprising a poly ethylene terephthalate substrate having a heat reflective solar control coating and a fifth sheet of an interlayer material, interposed between the fourth sheet of interlayer material and the second ply of glass.

14. The laminated glazing of claim 10, wherein at least one sheet of interlayer material has solar control properties.

15. The laminated glazing of claim 10, further comprising at least one of a solar control, heat reflective, low-emissivity, hydrophobic or hydrophilic coating.

16. The laminated glazing of claim 10, further comprising a third ply of glass, separated from the second ply of glass by an air gap.

17. The laminated glazing of claim 10, wherein the thickness of the suspended particle device film is the same as the first layer of interlayer material.

18. The laminated glazing of claim 10, wherein the fourth sheet of interlayer material is poly vinyl butyral.

19. The laminated glazing of claim 18, wherein the fourth sheet of interlayer material is coloured and/or has acoustic properties.

20. A laminated glazing comprising first and second plies of glass having an interlayer structure laminated therebetween, the interlayer structure comprising a first sheet of an interlayer material having a hole therein, there being a suspended particle device film positioned in the hole in the first sheet of interlayer material, the suspended particle device film being coplanar with the first sheet of interlayer material and being framed by the first sheet of interlayer material, a thickness of the suspended particle device film being the same as a thickness of the first sheet of interlayer material, the first sheet of interlayer material being directly laminated between a second and a third sheet of an interlayer material, wherein the interlayer material components of the first sheet do not comprise a plasticizer, or comprise a plasticizer that does not migrate into the suspended particle device film, wherein the first sheet of interlayer material is ethylene vinyl acetate copolymer, and wherein the second sheet of interlayer material is ethylene vinyl acetate copolymer and the third sheet of interlayer material is ethylene vinyl acetate copolymer.

21. The laminated glazing of claim 20, wherein a peripheral edge of the suspended particle device film is in direct contact with an interior edge of the first sheet of interlayer material, the interior edge of the first sheet of interlayer material defining the hole in the first sheet of interlayer material.

22. A laminated glazing comprising first and second plies of glass having an interlayer structure laminated therebetween, the interlayer structure comprising a first sheet of an interlayer material having a hole therein, the first sheet of interlayer material being directly laminated between a second and a third sheet of an interlayer material, there being a suspended particle device film positioned in the hole in the first sheet of interlayer material, the suspended particle device film being coplanar with the first sheet of interlayer material and being framed by the first sheet of interlayer material, wherein the interlayer material components of the first sheet do not comprise a plasticizer, or comprise a plasticizer that does not migrate into the suspended particle device film, wherein the first sheet of interlayer material is ethylene vinyl acetate copolymer, wherein the second sheet of interlayer material is ethylene vinyl acetate copolymer and the third sheet of interlayer material is ethylene vinyl acetate copolymer, and wherein at least one of the second and third sheets of interlayer material is in direct contact with and co-extensive with one of the first and second plies of glass.

23. The laminated glazing of claim 22, wherein the second sheet of interlayer material is in direct contact with and co-extensive with the first glass ply and the third sheet of interlayer material is in direct contact with and co-extensive with the second glass ply.

24. The laminated glazing of claim 22, wherein a peripheral edge of the suspended particle device film is in direct contact with an interior edge of the first sheet of interlayer material, the interior edge of the first sheet of interlayer material defining the hole in the first sheet of interlayer material.

Description

(1) The present invention will now be described by way of example only, and with reference to the accompanying drawings in which:

(2) FIG. 1, as referred to above, is a schematic plan view of a laminated glazing having an SPD film laminated therein;

(3) FIG. 2 is a schematic cross-section showing the construction of a laminated glazing having an SPD film laminated therein;

(4) FIG. 3 is a schematic cross-section showing the construction of a laminated glazing having an SPD film laminated therein, showing a second picture frame design;

(5) FIG. 4 is a schematic plan view of a laminated glazing having an SPD film laminated therein, showing a second picture frame design;

(6) FIG. 5 is a schematic cross section view of a further laminated glazing in accordance with the present invention;

(7) FIG. 6 is a schematic cross section view of a further laminated glazing in accordance with the present invention; and

(8) FIG. 7 is a schematic cross section view of a double-glazed structure including an SPD film in accordance with the present invention.

(9) It has been appreciated that there is at least one mechanism that influences the formation of the non-functioning or impaired edge region within the SPD film in a laminated glazing. By determining this mechanism, it has been possible to develop a laminated glazing where the presence of the border region within the SPD film is minimised or eliminated.

(10) PVB interlayer materials generally contain a plasticizer, which determines the rigidity and flexibility of the interlayer, as well as influencing the mechanical strength, as well as other components, such as additives to control resistance to UV (ultra-violet light). The clear region may be formed by the migration of plasticizer and other components of the PVB interlayer material into the SPD film. Either individually, or in combination, the plasticizer and additives may disrupt or interfere with the separation and suspension of particles, or the stability of the liquid pores. These effects result in a reduction in the function of the SPD film. The functionality of the border region is not uniform, and may give rise to a region that is dark in appearance and does not switch, or is bright in appearance and switches more intensely. In each case, the border region appears to fade out at the edge of the film. This observation supports the idea that the border formation mechanism is based on diffusion. Indeed, it is known that the diffusion rate of a mobile component within a host material increases with temperature, and observations have shown the border grows more quickly at higher temperatures. The appearance of the border region within the SPD film, and not surrounding the film in the interlayer indicates that the diffusion of plasticizer into the SPD film appears to dominate any diffusion of SPD particles out of the film into the surrounding interlayer material.

(11) The presence of plasticizer within the interlayer material is therefore an important factor in the creation of the border region within the SPD film. By the use of low plasticizer content or plasticizer free interlayer materials, or the use of plasticizers which do not diffuse into the film, the border region may be reduced in size or even eliminated, depending on the effect of other interlayer material components. Suitable interlayer materials include EVA (a copolymer of ethylene vinyl acetate), PVC (poly vinyl chloride) PU (polyurethane), PC (polycarbonate) and copolymers of ethylene and methacrylic acid. If an interlayer containing little plasticizer is used, preferably the amount of plasticizer contained therein is less than that of standard automotive PVB.

(12) In order to compare the effects of plasticizer-free interlayer materials with a PVB interlayer, two sets of samples were made, one set with a PVB interlayer structure and one set with an EVA (ethylene vinyl acetate) interlayer structure. The PVB interlayer used was a RZN-12 interlayer, available from Sekisui Chemical Co. Ltd, and the EVA interlayer used was an EN interlayer, also available from Sekisui Chemical Co. Ltd. FIG. 2 is a schematic drawing showing the construction of a glazing having an SPD film laminated therein. The glazing 4 has an SPD film 2 laminated within an interlayer structure 6, which is itself laminated between two plies of glass 7a, 7b. The laminated structure 6 comprises three layers of interlayer material, 8a, 8b, 8c. The first interlayer 8a also has a region cut out of the centre in which the SPD film sits, such that the first interlayer 8a forms the picture frame. Preferably the thickness of the SPD film 5 is of the same order as the first interlayer 8a. The first interlayer 8a is laminated between second 8b and third 8c interlayers, which are co-extensive with the plies of glass 7a, 7b. A peripheral edge 5e of the SPD film 5 faces an interior edge 8ae of the first interlayer 8a.

(13) Samples were prepared in the following manner. Firstly, the connectors were prepared. The SPD films used in the samples were polymer dispersed SPD films available from Research Frontiers Incorporated, 240 Crossways Park Drive, Woodbury, N.Y. 11797, USA. An electrical connection was made to each ITO (indium tin oxide) layer within the SPD film, whilst maintaining electrical isolation between the ITO layers.

(14) Secondly, once the soldering was completed, the samples were laid up for lamination. Three sheets of interlayer material (0.76 mm, 0.38 mm and 0.76 mm thick respectively for the PVB interlayer material, or 0.40 mm thick for all three EVA interlayers) were placed between the two plies of glass to be used to form the sample, and trimmed to the external size of the plies of glass. The SPD film was then used as a template to mark a hole in the sheet of 0.38 mm/0.40 mm thick interlayer material, and a hole cut approximately 1-2 mm oversize of the mark, to minimise contact between the interlayer material and the edge of the SPD film. This forms the picture frame in which the SPD film is placed. The sheets of interlayer material and SPD film were then laid up on the glass to create the structure shown in FIG. 2.

(15) Thirdly, the samples were laminated. Each sample was vacuum bagged and placed in an oven at 105 C. for 40 minutes. Once the lamination cycle had been completed, both samples were then heated at elevated temperature at atmospheric pressure for various time periods, in order to determine the extent to which a border region appeared under extreme conditions. Once this heating was complete, the samples were inspected visually.

(16) No border region was observed in samples having an EVA interlayer, but the width of the border region in the samples having a PVB interlayer increased with increasing temperature. These results indicate that the mechanisms discussed above, whilst not necessarily being the entire reason for the appearance of the border region, are likely to be dominant in its formation.

(17) When a glazing in accordance with the present invention is used as an automotive glazing, such as a rooflight, a sidelight or a backlight, it is desirable to be able to control the colour of the glazing. One way in which this may be done is to use at least one ply of glass which is tinted, for example, having an LT (light transmission) when measured using CIE Illuminant A of less than 87% at 2.1 mm. In particular, glasses such as those known as GALAXSEE and SUNDYM, available from Pilkington Group Limited, may be used. Preferably the plies of glass used are annealed or semi-toughened before lamination.

(18) An alternative approach, when at least one ply of clear (having an LT of greater than 88%, measured using CIR Illuminant A) is used, is to include at least one layer of a tinted PVB in the laminated structure in which the SPD film is placed. However, as discussed above, any plasticizer within the PVB may affect the structure and appearance of the SPD film. In order to prevent this, it is desirable to remove any contact between the edge of the SPD film and the PVB interlayer. This may be done in a number of ways, for example, by using coloured EVA interlayers. Alternatively, colour may be added (by means of a dye, for example) to the PET interlayers which form the substrates of the SPD film 5. The amount of colour used may vary from a low level of tint, to hide any off-white colour of the SPD film 5 when not in use, to heavily tinted to provide some thermal and/or optical control to the glazing.

(19) Alternatively, a coloured PVB interlayer may be included by means of a second picture frame construction. FIG. 3 is a schematic cross-section of the structure of a glazing 9 having a second picture frame construction. An interlayer structure 10 is laminated between two plies of glass 11a, 11b. The interlayer structure 10 comprises four layers: an upper layer 12a, formed of a coloured PVB, which is co-extensive with the upper glass ply 11a, a second picture frame layer 12b, formed of a plasticizer free, or low plasticizer material, such as PET, a first picture frame layer 12c, containing the SPD film 5, and a lower layer 12d, formed of a plasticizer free, or low plasticizer material, and co-extensive with the lower ply of glass 11b. The second picture frame layer 12b prevents the edge of the SPD film 5 from coming into contact with the coloured PVB interlayer, thus preventing degradation of the SPD film 5. The coloured PVB interlayer 12a may contact the SPD film 5 in a central region, to ensure adhesion within the interlayer structure 10. A peripheral edge 5e of the suspended particle device film 5 faces an interior edge 12ce of the first picture frame layer 12c.

(20) FIG. 4 is a schematic plan view of a glazing having a first picture frame layer 12c (represented by a dotted line) containing an SPD film 5, showing the second picture frame layer 12b overlapping the first picture frame layer 12c. Busbars 13a, 13b and electrical connectors 14a, 14b are provided to allow the sample to be connected to a power source.

(21) For a glazing to be included in a vehicle, for example, as a rooflight, the busbars and electrical connectors between the SPD film and the wiring harness of the vehicle may be hidden by an obscuration band. This is a band of fired, black ceramic ink around the edge of the upper ply of glass, which acts to cover the adhesive holding the glazing into a vehicle, and electrical connections. The purpose of the band is two-fold, firstly aesthetic, and secondly, to prevent damage of adhesive or other components from UV exposure. The obscuration band may also hide the edges of the SPD film.

(22) When a coloured EVA interlayer material is used in the glazing construction, or a coloured PET substrate used in the manufacture of the SPD film, a clear PVB interlayer material having acoustic properties may be used. Alternatively, a coloured acoustic PVB interlayer material may be used.

(23) FIG. 5 is a schematic cross section view of a glazing 15 comprising a five-layer interlayer structure 16 laminated between two plies of glass 17a, 17b. Preferably, the upper ply of glass 17a is clear, and is provided with a heat reflective solar control coating on its inner surface. The lower ply of glass 17b may be clear or tinted. The interlayer structure 16 comprises a first interlayer 18, a second interlayer 19, having an SPD film 20 incorporated therein, a third interlayer 21, a PET substrate 22 and a fourth interlayer 23. Preferably, the first 18, second 19 and third 21 interlayers are formed of EVA or other suitable interlayer material, as discussed above. The fourth interlayer is preferably a tinted PVB interlayer. In addition, the PVB interlayer may have acoustic or solar/thermal control properties. By using a five-layered interlayer structure, a barrier is provided between the SPD film 19 and a PVB interlayer, removing any issues due to interlayer component migration.

(24) It may be desirable, as an alternative to using a coated glass to provide solar control, to use an interlayer material which provides a degree of solar control. For example, additives such as pigments or nanoparticle systems including LaB.sub.6 or ITO (indium tin oxide), are known for use with PVB interlayers, and may be used in an EVA interlayer in the laminated glazing structure of the present invention.

(25) However, rather than using a solar control interlayer or providing a coating on one of the plies of glass, it may be desirable to include a solar reflective, in particular, a double-layered silver coating, on a PET substrate included within an interlayer structure in a laminated glazing. FIG. 6 is a schematic cross section view of a further laminated glazing in accordance with the present invention, and shows a glazing 24 comprising a seven-layer interlayer structure 25 laminated between two plies of glass 26a, 26b. Preferably, the upper ply of glass 26a is clear, although the lower ply of glass 26b may be clear or tinted. The interlayer structure 25 comprises a first interlayer 27, a second interlayer 28, having an SPD film 29 incorporated therein, a third interlayer 30, a first PET substrate 31, a fourth interlayer 32, a second PET substrate 33, having a double silver layer solar control coating, and a fifth interlayer 34. Preferably, the fourth interlayer 32 is a tinted PVB interlayer, and the fifth interlayer 34 a clear PVB or other suitable interlayer material. By using a coated PET substrate to provide solar control and a tinted PVB interlayer, it is possible to produce a colour control glazing without needing to use heavily tinted glasses.

(26) Particularly preferred glazing constructions utilise EVA interlayers only. These interlayers may be combined with a coating on either ply of glass, or with a coated PET substrate to provide appropriate solar control.

(27) Preferably, when a tinted interlayer material is used, it is colour matched to a tinted glass, such as GALAXSEE or SUNDYM, available from Pilkington Group Limited, or a blue, grey or green glass.

(28) Suitable functional coatings for use with such a glazing construction when used as a rooflight include low-emissivity coatings, conductive coatings and solar control coatings. A low emissivity coating is a coating which when applied to clear, 3 mm thick float glass, results in the coated glass having an emissivity in the range of 0.05 to 0.45, the actual value being measured in accordance with EN 12898 (a published standard of the European Association of Flat Glass Manufacturers). Hard coatings generally have emissivities between 0.15 and 0.2, whereas off-line coatings generally have emissivities of 0.05 to 0.1. As a comparison, uncoated 3 mm thick float glass has an emissivity of 0.89.

(29) A hard (or pyrolytic) low emissivity coating may comprise a single layer of a metal oxide, preferably a transparent, electrically conductive oxide. Oxides of metals such as tin, zinc, indium, tungsten and molybdenum may be present in the metal oxide layer. Typically, the coating comprises a further dopant, such as fluorine, chlorine, antimony, tin, aluminium, tantalum, niobium, indium or gallium, for example, fluorine-doped tin oxide or tin-doped indium oxide may be used. Such coatings are generally provided with an underlayer, such as silicon or silicon oxynitride. The underlayer acts as a barrier to control migration of alkali metal ions from the glass and/or to suppress iridescent reflection colours caused by variations in thickness of the low emissivity layer.

(30) Off-line (typically sputtered) low emissivity coatings typically comprise a multilayer coating stack, normally including at least one metal layer or electrically conductive metal compound layer, and a dielectric layer. Silver, gold, copper, nickel or chromium may be used as the metal layer, whereas indium oxide, antimony oxide or the like may be used as the electrically conductive compound. Typical multilayer stacks comprise one or two layers of silver deposited between layers of a dielectric such as an oxide of silicon, aluminium, titanium, vanadium, tin, or zinc. Individual layers of such coatings are typically tens of nanometers in thickness. Low emissivity coatings may be provided on either surface of the upper and lower plies of glass in the laminated glazing structure, depending on the combination of interlayers used and desired thermal performance.

(31) Typical solar control coatings comprise layers of silver or tin oxide, and control the amount of heat absorbed through the coated glass. Solar control and low emissivity coatings may also be electrically conductive, and so not only provide functionality to the glass in terms of emissivity and heat transmission, but can form an electrically conductive substrate for mounting electrically conductive devices such as LEDs, sensors and cameras.

(32) A heat reflective solar control coating, for example, a two-layer silver coating, may also be used. Typically, the solar heat reflected by such coatings is greater than 23%, measured in accordance with ISO9050:E (2003), air mass 1.5. Metallic heat reflective coatings may also be electrically conductive, and are particularly useful if the outer ply of glass is of clear glass. Such coatings are typically provided on the inner side of an outer ply of clear glass.

(33) Alternatively, the SPD film may be included within a double-glazed structure. FIG. 7 is a schematic side view of a double-glazed structure 35 including an SPD. The double-glazed structure 35 comprises any of the laminated glazing structures described above, generally represented by reference number 36 in FIG. 7, in combination with an additional upper ply of glass 37, and separated from the glazing structure by an air gap 38. The additional upper ply of glass 37 is toughened and preferably tinted, for example, a dark tint such as that sold as GALAXSEE, available from Pilkington Group Limited.

(34) The advantage of using a structure including a heat reflective coating (either on a ply of glass or on a separate interlayer) or a double glazed structure including an air gap is that the amount of heat absorbed by the SPD film can be reduced. As the migration of plasticizer and other interlayer material components is a diffusion process, any extra heat absorbed by the SPD film will increase the size of the clear border region. This is a particular problem for glazings that will be used as rooflights in vehicles, where the SPD film may become damaged in-situ.

(35) The present invention therefore provides a glazing which is switchable to alter the amount of light entering a vehicle through the glazing.

(36) Further embodiments of the invention, within the scope of the appended claims, will be apparent to those skilled in the art.