ASYMMETRICAL GLASS LAMINATES HAVING A TPU INTERLAYER AND RELATED METHODS

Abstract

Various embodiments for a laminate glass article and related methods are provided. The laminated glass article includes a first glass layer and a second glass layer with a TPU interlayer positioned therebetween.

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 thermoplastic urethane.

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

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

4. The article of claim 1, wherein the first CTE is greater than the second CTE.

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

6. The article of claim 1, wherein the first CTE is greater than 75×10.sup.−7/° C.

7. The article of claim 1, wherein the second CTE is less than 60×10.sup.−7/° C.

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

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

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

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

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

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

14. The article of claim 1, wherein the interlayer comprises a thickness of at least 0.76 mm to not greater than 2.3 mm.

15. The article of claim 1, wherein a total thickness of the first layer is between at least 2 mm and not greater than 12 mm.

16. The article of claim 1, wherein a total thickness of the first layer is between at least 3 mm and not greater than 6 mm.

17. The article of claim 1, wherein a total thickness of the first layer is between at least 2 mm and not greater than 7 mm.

18. The article of claim 1, wherein the interlayer thickness ranges from at least 1 mm to not greater than 2 mm.

19. The article of claim 1, wherein the thickness of the laminate is not greater than 15.3 mm.

20. The article of claim 1, wherein the thickness of the laminate ranges from 4.25 mm to 8 mm.

21-44. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0070] 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:

[0071] FIG. 1 is a schematic depicting an embodiment of a laminate, in accordance with various embodiments of the present disclosure.

[0072] 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.

[0073] 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.

[0074] FIG. 4 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.

[0075] FIG. 5 is a schematic depicting another embodiment of a triple pane window including a laminate, in accordance with various embodiments of the present disclosure.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] 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

[0080] 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.

[0081] Referring to FIG. 1, a laminate 100 is depicted. 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 102 and the second glass layer 104 is the interlayer 120, which comprises a TPU layer 122 (having a first side 124 and second side 126). The first side 124 of the TPU layer 122 is positioned adjacent to the second side 106 of the first glass layer 102. The second side 126 of the TPU layer 120 is positioned adjacent to the second side 116 of the second glass layer 112. FIG. 1 depicts a monolithic laminate, in that each of the layers: first glass layer 102, TPU layer 122; and second glass layer 112 are adhered together in an integral form (e.g. optically transparent).

[0082] 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 126 retained (e.g. along its perimetrical edge) in a frame 108.

[0083] 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 comprising a laminate 100 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.

[0084] 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 and the third pane is a laminate. 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.

[0085] FIG. 5 depicts an alternative embodiment for a triple pane window 100 having a laminate 100 as the first pane 148, where the laminate is as described in FIG. 1 and the triple pane window is as otherwise described in FIG. 4.

[0086] FIG. 6 depicts a laminate 100 having the configuration described in FIG. 1, configured as a window 110. As shown in FIG. 6, 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 also configured as 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.

[0087] 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.

[0088] FIG. 8 provides an example method of making a laminate, in which a plurality of layers are 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.).

[0089] 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

[0090] In order to evaluate the interlayer configuration's effect on bow mitigation, an experiment was performed where two (2) 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.

[0091] An embodiment having TPU as the interlayer was evaluated against a Control having polyvinyl butyral (PVB) as the interlayer. 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 respective interlayer having an equal thickness (embodiment vs. control).

[0092] The same method of lamination was utilized to process all samples, in that the interlayer was 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.

[0093] The resulting laminates, each had the same dimension of 1100×900 mm, were evaluated for bow (1) in the diagonal across the laminate and (2) along the long edge of the laminate.

[0094] 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 (long edge bow). 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).

[0095] The table below provides the resulting bow measurements for each of the laminates.

TABLE-US-00001 % Bow Post-Lam decrease Interlayer Second Long vs. Control First layer Type/ layer Post-Lam Edge (avg. bow Sample Thickness, Thickness Thickness, Diagonal Bow reduction vs. Description mm (mm) (mm) Bow (mm) (mm) control) Control 2.1 PVB/ 0.7 4.58 4.23 Control, N/A (non-invention) 2.29 Embodiment 2.1 TPU 2.29 0.7 0.84 0.80 81.4%

[0096] As shown in the table above, the embodiment significantly outperformed the control. Under identical processing conditions, the embodiment demonstrated over five times less bow compared with an approximately equal thickness of PVB. In evaluating the average bow, the bow was calculated to be over an 80% decrease from that of the control, a significant improvement.

[0097] 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

REFERENCE NUMBERS

[0098] Window 110 (e.g. also called an insulating glazing unit) [0099] Frame 108 [0100] Seal member(s) 118 [0101] First pane 148 [0102] Second pane 128 [0103] Third pane 136 [0104] Fourth pane 138 [0105] Air gap 1 150 [0106] Air gap 2 152 [0107] Air gap 3 154 [0108] Laminate 100 [0109] First glass layer 102 (e.g. high CTE, thicker, SLG) [0110] First side of first glass layer 104 [0111] Second side of first glass layer 106 [0112] Second glass layer 112 (e.g. low CTE, thinner, non-SLG) [0113] First side of second glass layer 114 [0114] Second side of second glass layer 116 [0115] interlayer 120 [0116] TPU layer 122 [0117] First side of first TPU layer 124 [0118] Second side of first TPU layer 126